Bwwwaaaaahhhhhaaa!! It has begun!!!!

[elerner]

The car is up, the oil is out and I called it a short night right after I pulled off the upper intake manifold. Can't wait to get more done tomorrow night. If I'm verrrry lucky I'll finish up Friday night.

[Tom @ Fast Forward]

So, how long was the un-install?

[elerner]

Went at it again last night. Had trouble loosening the EGR tube 22mm nut, but eventually got it. I couldn't disconnect the injector connectors so I had to wrap the harnesss while it was in place (not hard, just time consuming). But the biggest PIA was the bottom lower manifold nuts. Man!, those are in a tough spot. Taking off the oil filter was a great suggestion! When I finally broke the last nut free I almost cried (it was midnight).

So far I'm about 6 hours into it total. Gonna throw in a set of Mazdaspeed motor mounts I got before putting the blower on.

More to report later on.

Tom, have you got the harness wire identified for the CAS?

Thx.

[socal pat]

I had exactly the same experience with the EGR (skipped it) and the injector clips as well (skipped them too). You're now about 1/2 way home :D Just have to get those Intake manifold nuts back on :P It will all be worth it in the end!

[elerner]

Any tips on how you got the lower nuts back on? How did you eventually do it?

I wasted a good amount of time trying to get them off from underneath. Eventually I just got my hands in there from above, prayed I didn't round off any of the nuts and grunted and groaned through it. I think I almost shed a tear of joy when the last one "cracked" free.

[Banshee]

I finger tighten them, then using various extension and the 12mm crowfoot wrench, I tighten them from above. If you removed the alternator, you can tighten the 2 front one from below. It's not bad at all.

[99mx5]

I just used an open end wrench to get the last two nuts. The wrench fits behind the starter. With the car on ramps, and you under the car, you can reach with the left arm into the wheel well to steady the wrench from above the starter and the right arm up by the alternator to reach and push to tighten the wrench behind the starter. Loosening is basically the same.

[raceskier]

I used a 12mm crowfoot as well. I think starter, alternator and fuel pressure dampener bracket R & R might be the way to go as far as overall installation time goes, just to access those lower nuts.

[elerner]

Well, I finished the install yesterday and started her up around 5pm. Took her out for a test spin and it took a while to begin taking in how differently it drives now. It pulls really nicely in 1st and second gear, redline comes pretty quickly but something still isn't right though, After talking with Tom I'm either running out of fuel or maybe my CAT is clogged. When accellerating it seems like only the first 1/2 of the gas pedal action has any affect. Putting my foot in it more than 1/2 way doesn't seem to have any affect. Took it out today at lunch and it through a CEL very quickly. I can't be exactly sure, but it may have thrown the CEL after it was sputtering a little as I pulled out of the driveway. The sputterring seems to go away very quickly. On one "spirited" stretch I think I heard the "pebbles rattling" sound in my CAT.

I found a local mechanic who has done some tuner work. I'm going to bring it by tomorrow and see if he can read the CEL code. I checked out the JRPC lights today with Tom and all seems well. Bought a serial cable tonight and tomorrow I'll hook up to the SS with a laptop and see what that says.

I think there's a new CAT in my future. I've got a Goodwin Roadster muffler. Their midpipe/CAT would seem the logical choice. Opinions on this?

This install was by far the biggest mechanical undertaking. I labeled all the parts I took off, double/triple checked all my work and tried to get a torque wrench on just about every bolt and nut. In the end, the extended install time spread over 5 nights/days probably caused the increased stress I've been feeling. Oh well, time to get over it and get past these final nits.

One final word, Tom has been fantastic. Always accessable, even over the weekend. His customer service approach makes all the difference. Thanks Tom!

[ThomS]

Well on my install I am up to 57 hours total so far and still not done. But you are right, Tom has been greateven accessable even on holiday July 4th. Thanks Tom. Great service above and beyond....

[Banshee]

57 hours :shock: :shock: ? How much beer was there?

[ThomS]

none sorry to say..I wish that was the excuse.

[Banshee]

Thoms, Do you have a boost gauge? If you do, can you tell me how much boost you are seeing with your 105 pulley?

[ThomS]

BANSHEE I do not have a boost gauge but when i get it dyno done if I ever get it started I will tell you that info. If I install a gauge if you think it is important I will also tell you then but that wont be for a while.. Sorry. I wish I could help you , you have been so good with info to me.
Thom

PS. now 59 hours. almost done. :roll:

[Tom @ Fast Forward]

Thom,

Right is better than fast. Take your time and do it right and you will only do it once.

[Dr Evol]

Thom, you can use a laptop and the SS to see what your boost levels are. I can bring my laptop to one of the next events. We can take your car out on the street for a drive and we can see what your boost levels are if you are intertested.

[Kyp J]

Thom,

Right is better than fast. Take your time and do it right and you will only do it once.

Ha! Famous last words.

I just picked up my engine from the machine shop. I should start logging my time to see how long to install engine, clutch, midpipe, radiator, super charger and cooling reroute.

It is really hard to log since I have to take a lot of naps between various stages.