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Discussion Starter · #61 ·
Following on from my thread HERE

I got the results for the MOT emissions test:
Fast Idle CO(%): Limits Max: 0.30, Actual Value: 8.88!
Second Fast Idle CO(%): Limits Max:0.30, Actual Value: 9.14


Not good, not good at all!

So, where to begin....throughout this whole debacle I've tried to resist doing anything with the Mazdaspeed engine, a rebuild of any sort and it would be more economical to swap the engine. With that, the inevitable has happened and at this stage I'm so far down the rabbit hole giving up would be a financial mistake x_x so the decision is made, out the engine comes.

We're committed!

I've never swapped an engine before, but I've watched a few You-tube videos, so that's about the same right?

First things first, drop the fresh oil that went in 20 miles ago:
25241060627_13f9b0ddd6_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr
Oh dear, that's not a good sign x_x

Next, remove the radiator and any attached hoses wires, taking care to label everything for ease of re-installation, I'll need a new radiator fan as it's pretty beat up.
40080553432_99a51c6c8f_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr

We decided to leave the gearbox in the car, having already swapped the clutch we knew what to expect regarding bell housing bolts etc. Only tough points were disconnecting the starter motor electrical connections. Engine ready to be removed:
40080553582_0f0a218730_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr
Engine out, the bays covered in a lot of oil:
25241060327_a8fd126d13_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr
Old engine right and replacement left:
40080553002_fbdcac99a4_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr
Decided to swap over the starter and alternator as we knew they worked, also changed: rubber fuel lines, oil cooler rubber hoses, oil filter, rear camshaft seal, coolant hoses, many many hose clips that had perished.

MOT failed on an oil leak at the rear of the block, the likely culprit being the CAS O-ring, looked like it had never been changed since the factory, brittle like plastic with no play. For anyone that hasn't changed this I'd recommend getting it done, the heater hose below hadn't burst with oil dripping on it, but it wasn't in good condition and couldn't have been far off.
25241060507_27d9850103_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr
25241060427_c6a5851487_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr

After that it was a case of getting the replacement engine into the car, not as bad as expected, it can be done leaving the box in place. I'm not sure there would be much time difference between the two methods.
40080553172_4df8c4904b_c.jpgMX5-NA 05/02/2018 by Scott Reid, on Flickr

So that's how it sits currently: exhaust manifold, air intake, new oil and new coolant are to be sorted then we can see if it starts and how well it runs.

I've still to get replacement exhaust gaskets, engine mounts, a ball joint and some dust covers. Plus a new radiator fan an lower radiator mounting brackets as they're toast.

Once we've confirmed it works and passed an MOT, the engine will get new plugs, leads, water pump and cam-belt.

So the project lumbers on, not quite as special as before, but at least it might actually get on the road this year!
 

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Good work on getting the other engine in so quickly, hopefully it gets through the MOT this time! Good that you've got all the seals and hoses changed when the engine is out - a lot easier that way.

My CAS o-ring was the same, turned to plastic.
 

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Well done on getting that done! How long did it take you to swap the engine?

Whens the first turn of the key going to be?
 

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Discussion Starter · #64 ·
Good work on getting the other engine in so quickly, hopefully it gets through the MOT this time! Good that you've got all the seals and hoses changed when the engine is out - a lot easier that way.

My CAS o-ring was the same, turned to plastic.
Some of those would have been a real pain if the engine was still in, oil cooler lines would be a manifold off job I'm sure. So many pipe clamps are corroded so badly they just snap in position, getting them removed is a real chew!

Well done on getting that done! How long did it take you to swap the engine?

Whens the first turn of the key going to be?
Roughly 2.5 days, but we had access to a lift and serviced a lot of components. I'm sure we could do it a lot quicker now though.

First start up was today, started first time :banana:
 

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Well done on getting that done! How long did it take you to swap the engine?

Whens the first turn of the key going to be?
Roughly 2.5 days, but we had access to a lift and serviced a lot of components. I'm sure we could do it a lot quicker now though.

First start up was today, started first time :banana:
Fairly Good time then!

And great to hear!
 

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hey Scotty, sorry to hear about the engine. hopefully the "newer" one will be a good one

at least you're not affraid to get your hands durty :yes:

any plans for the "old" engine?
 

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Discussion Starter · #67 ·
hey Scotty, sorry to hear about the engine. hopefully the "newer" one will be a good one

at least you're not affraid to get your hands durty :yes:

any plans for the "old" engine?
Thanks mate, one of those things you just need to jump in to a learn along the way.

Plan is to rebuild it and put it back in, but that won' be until 2019 I wouldn't think.
 

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Discussion Starter · #68 ·
Update:

So the car passed it's MOT in the middle of February, on a UK car emissions test criteria, despite us telling them and supplying documentation to suit....but it passed so that's fine. Whilst away it got a wheel bearing and some dust boot covers replaced.

With the weather cleared up, I headed north to spend some time on the car. Not as many photos this time around, but a lot of the work you can't see anyway.

We were all set to service the water pump and timing belt, but this looks to have been done very very recently on the replacement engine, so the plan is to run it for a summer and change it all next year.

Swapped the cam cover with one that I'd spent some time painting (wrinkle black VHT paint, with exposed lettering), along with fitting a Stoney Racing brake booster one way valve and silicone hose. Also changed the rubber grommets, where the heater matrix pipes penetrate the firewall.

39867741205_d2a2bf5cdf_c.jpgMX5 NA10/03/2018 by Scott Reid, on Flickr

Going by all rubber that's been changed so far, we'll be swapping out the rest in due course.

Other things completed:
New Radiator and Radiator Fan.
New Oil Cap.
New Polybush mounts for front ARB.
New bulbs for headlight/sidelight.
New drivers side light cover.
New passenger side light cover (carbon fibre).
Jass Performance Brake Stopper fitted.
Removed and cleaned window wiper mechanism (they'd almost seized).
Remove snapped bolts for the undertray.

39867740885_282a1486ee_c.jpgMX5 NA10/03/2018 by Scott Reid, on Flickr

Big jobs still to do:
Adjust timing to 14 degrees and idle to 800rpm.
Change roof (again) and wire in HRW.
Suspension pre-load/ride height adjust, then alignment.
Replace callipers, pads, brake lines and brake fluid all round.

Open to opinions on the CF light cover, it seems to split opinion. Maybe after all other mods are on it won't stick out so much (poor photo doesn't help) :
40052911224_e283375d34_c.jpgMX5 NA10/03/2018 by Scott Reid, on Flickr

Hopefully more to come soon, maybe some pictures out of the garage :D
 

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Discussion Starter · #69 ·
So, since the car passed it's MOT last month, work has continued to get it on the road officially as well as a bit of wheeling and dealing.

I seem to have amassed some parts I'll never need or that have been replaced, so in an effort to clear some space had minor clear out, this included the Bronze 15x7" ET30 Wheels with Toyo T1-R.
36716199602_df1c4bc2f9_c.jpgMX5 29/08/2017 by Scott Reid, on Flickr
Why were these sold? Managed to pick up a set of 14"x6 ET40 Panasport fitted with some Avon tires, a case of right place right time. Quoted at roughly 13.3kg each (including tire), a stark comparison to the 19kg each wheels/tires they replaced.

What is it they say? 1kg of un-sprung = 10kg of sprung weight? Hopefully that makes a difference, but I've no starting point for a comparison.

Other things that have been completed: new roof has been fitted and seems to have added head clearance as well as improving the exterior as it's actually black, HSD's pre-load adjusted from rock solid back to stock.

Some issues still persist though:
- Idle is around 1000-1200rpm and in our search for the cause we have replaced the rear coolant temp sensor, had the throttle body off to try clean out all idle control parts, searched for any air leaks. Next step is replaced the whole thing and try again.
- Manifold bodge is leaking at the reducer, it's going to have to be replaced and fixed off the car, so the hunt for a replacement manifold on-going.
- Underseal, paint, dents!

I digress though, after almost a year of ownership, the car is now ready for the road and my first time driving it. Gratuitous first drive shots:
40675257035_5b4696d1a6_c.jpgMX5 NA 19/04/2018 by Scott Reid, on Flickr
41568234431_bf893f9d43_c.jpgMX5 NA 19/04/2018 by Scott Reid, on Flickr
40675256875_96f72e38b4_c.jpgMX5 NA 19/04/2018 by Scott Reid, on Flickr
40675256725_5e1055b639_c.jpgMX5 NA 19/04/2018 by Scott Reid, on Flickr

Absolutely love it, without trying to waffle on about stuff that's been covered before, it really is a much rawer driving experience and with the HSD's adjusted towards soft it's actually quite comfortable (if you avoid pot holes and drain covers).

Odd quirks I've noticed are driving with the pop-ups up is bizarre, the side mirrors are really far back and these make a passing Ford Focus look HGV huge!

I'll make a list of everything that has been done another time, but for now, here's a before (May 2017) and after (April 2018):
24687285918_a3997f94cc_c.jpgMX-5 NA Day 1 by Scott Reid, on Flickr
41568233771_078ec62fbb_c.jpgMX5 NA 19/04/2018 by Scott Reid, on Flickr

Thanks for reading.
 

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Wow! Looks like a completely different car! Bravo!! And finished off just in time for this weather too :thumb-up:
 

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What a difference! Just gone through the whole thread and that last picture looks awesome! Props man.

Sent from my iPhone using Tapatalk
 

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Discussion Starter · #72 ·
Wow! Looks like a completely different car! Bravo!! And finished off just in time for this weather too :thumb-up:
Exactly! although it was meant to be ready for last summer :whistle:

What a difference! Just gone through the whole thread and that last picture looks awesome! Props man.

Sent from my iPhone using Tapatalk
Thanks mate :thumb-up:
 

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Discussion Starter · #75 ·
Brilliant transformation. Great choice on the panasports too, looks lovely
Thanks, yeah they look great, I can see why they are a popular choice. It was your comment on how heavy the bronze wheels were that initially planted the seed of doubt :D hopefully see you at a couple of runs this year, once the weather decides what it's doing.

great transformation, looks great now :thumb-up:
Thank you, the other half gets to see it for the first time finished this weekend, let's see if it's still looks "death trap"-esque!
 

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Discussion Starter · #76 ·
Minor update time:

Admitted defeat on my hunt for an aftermarket 1.8 manifold, I've gone for this manifold HERE, arrived a day earlier than expected and they've stated it's for a 370mm cat (which is ideal).

Quality seems ok, will advise what the fit it like:
40074337370_2f383f2e9f_c.jpgMX-5 NA 04/05/2018 by Scott Reid, on Flickr
41838981182_35ba934120_c.jpgMX-5 NA 04/05/2018 by Scott Reid, on Flickr
40074337290_efde80e779_c.jpgMX-5 NA 04/05/2018 by Scott Reid, on Flickr

By the time you factor in all gaskets, fittings and (manifold dependant) a new cat/decat. It seems worth a go, plan is to fit with the silenced decat and see how we get on.

Purists need not fear, the plan is to fix the RSR manifold and refit it at a later date.

Also fitted some centre caps to the Panasports, I think they look pretty decent, open to opinons though
40074337220_a7925b3101_c.jpgMX-5 NA 04/05/2018 by Scott Reid, on Flickr

Thanks for reading.
 

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Discussion Starter · #77 ·
Update:

Spent the majority of the weekend past sorting out the car, ready for the MX5OC Gathering at Braemar, on the Sunday.

Firstly, removing, cleaning and refitting the passenger electric window as it was slow as! It's improved but I think the motor has all but given up. Refitted door weather seals using gutter sealant of the "non-hardening" variety, hopefully it does better than the silicone used last time.
40805084270_b8e2200caf_c.jpgMX5 NA 05/18 by Scott Reid, on Flickr
Also fitted my new door cards, supplied by mx5mods and the Jass Performance door pulls. Both are excellent pieces of kit and really improve the interior which was starting to look a little tired. Also fitted; Jass Performance sport gear knob, Vent Surrounds, HVAC Knobs and Handbrake Handle.
28739671788_b8f46646a0_c.jpgMX5 NA 05/18 by Scott Reid, on Flickr
42562209132_9c921284ba_c.jpgMX5 NA 05/18 by Scott Reid, on Flickr
Fitted the Carbon surround to the gauges and Jass Performance brushed needle cap covers:
42562208632_30fe79b616_c.jpgMX5 NA 05/18 by Scott Reid, on Flickr
Also deleted the charcoal canister, no photos of this, but there's plenty guides around for those interested. It's exposed some corrosion in the engine bay that'll need some sorting sooner rather than later.

Also fitted some window toggle switches to match the rest of my switch gear, another Facebook 2nd hand purchase:
42562208072_e04ee481f8_c.jpgMX5 NA 05/18 by Scott Reid, on Flickr
Next steps for the interior are flock the gauge cowl and try dying the seats as they are really letting it down now.

Went to the gathering on the Sunday, met up with the Grampian bunch for a run to Braemar beforehand, roughly 12 cars in a convoy. It was absolutely roasting, so a great day for it in the end.
42562208512_25e6e4e6df_c.jpgMX5 NA 05/18 by Scott Reid, on Flickr
42600329341_feb01f7fef_c.jpgMX5 OC Gathering 05/18 by Scott Reid, on Flickr
41880633694_6f3958bdbb_c.jpgMX5 OC Gathering 05/18 by Scott Reid, on Flickr

Got to say, loving the new ND RF, I think it'd be the one I chose if given the option. This weekend I'm finally taking the car down to our new house. Me and a mate are going to drive down at the weekend, trying to catch as many good roads as possible, but I'll save that for a future update (I hope it makes it).

Cheers,
Scott
 

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Discussion Starter · #78 ·
The time finally rolled round that the car was finished and ready to be driven from my parents to my new house, roughly 160 miles. So what do you do; stick your friend on the insurance, plan a road trip with a route that collects some of the best driving roads you know (roughly 380 miles) and watch as the weather decides to throw a yellow warning for rain.......maybe not that last part.

The route took us up to Inverness, across to Applecross and down the west coast to Glasgow, passing through Fort William and Glencoe. We managed about 70% with the roof down, before the rain really started.

Just after Inverness:
42672851172_d6f2c3d854_c.jpgMX-5 Road Trip by Scott Reid, on Flickr

Halfway up the road to Applecross:
40911394580_3728268e30_c.jpgMX-5 Road Trip by Scott Reid, on Flickr
42672850032_f7e3d76701_c.jpgMX-5 Road Trip by Scott Reid, on Flickr

Obligatory Applecross sign photo:
40911394920_f47492d104_c.jpgMX-5 Road Trip by Scott Reid, on Flickr

Eilean Donan Castle (Near Isle of Skye):
42672850302_a933a7b837_c.jpgMX-5 Road Trip by Scott Reid, on Flickr

Only major issue is that the alignment is suicidal in standing water of any depth, so that's on the list next. It's done 1100+ miles since the engine swap and hasn't used any coolant or oil in that time.

No major updates to come, just fix a few niggles and get out and enjoy it over summer.

Thanks for reading.
 

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Should really have kept this up to date, but a lot has happened since my last update. The cars now been on the road since mid-2018 and been through three MOTs in my time of ownership. In the end the engine was swapped after discovering it was just a standard unit, where the B-Spec went will remain a mystery. To date the only things that haven't been removed at some stage are the dash and the fuel tank.

42095004750_997185dc5a_c.jpgMX5 08/18 by Scott Reid, on Flickr
49665402063_b3f01149ae_c.jpgPSX_20200212_125001 by Scott Reid, on Flickr
49459545421_6ee4811c5e_c.jpgIMG_20200127_001642_163 by Scott Reid, on Flickr
49666225497_9585a9e598_c.jpgPSX_20200310_173115 by Scott Reid, on Flickr
49665945221_a13e0a0868_c.jpgPSX_20200310_172853 by Scott Reid, on Flickr
49675845391_b9c6e0c8eb_c.jpgPSX_20200316_140432 by Scott Reid, on Flickr

Will keep this up to date with any future work, thanks for reading.
 

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Discussion Starter · #80 ·
Who would have thought the Auto-Solo in March would be just before lock-down, lucky to get the car out and try it out in the grand scheme of things.

Like most, I've spent time going through projects I've had on the go or planned to do.

Started by splitting a spare set of rear lights as a trial, then splitting and fitting LED rings to the side lights, as well as fitting LED bulbs to all external lights (bar the number plate):

49742061497_71e5aa83e9_c.jpgIMG_20200326_171014 by Scott Reid, on Flickr
49934570116_8e446cdc42_c.jpgIMG_20200403_171810 by Scott Reid, on Flickr

Painted a chrome rad cowl in stonechip black, replaced ARC intake chamber hoses with red:
49934054178_e05145c757_c.jpgIMG_20200418_154610 by Scott Reid, on Flickr

I'm also selling the ARC Intake chamber if anyone is interested.

Fitted a knock of Stebbel horn, as hated the stock option:
49934054578_95cfc52927_c.jpgIMG_20200418_154042 by Scott Reid, on Flickr

Located the source of my oil leak, thankfully not the rear crank seal we had already changed, but the front crank seal:
49934874587_3ef96415fe_c.jpgIMG_20200413_185831 by Scott Reid, on Flickr

Fitted a ducktail to a spare bootlid I had laying about, much prefer it to the R-package spoiler:
49934875752_2c55f2442f_c.jpgIMG_20200401_175927 by Scott Reid, on Flickr

I'll do a separate post for the BP4W swap as there's quite a lot to fit in.
 
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