Lewis7789 2002 Protege5 build thread (tons of pics)

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Hello!
long time fan and follower of the thread, I have just a few questions.
Did you cut up your stock harness?
Did you consider Megasquirt when doing your install?
Besides the engine/tranny what else did you have to buy?

I ask because i'd love to do a similar swap (but @ 4 psi :D), but I live in a emissions restricted area. I'm thinking the only way to get around is to swap in the old 2.0 every time i need to pass (I know, I know). At the moment I'm only teasing the idea.
I was reading a thread on another forum about a guy who did it, but did with MS and made his life much easier. So while the idea of getting a DIYPNP kit is daunting, I found this:

http://www.stratifiedauto.com/index.php?main_page=product_info&cPath=66&products_id=209

I'm thinking this would make the new engine almost a drop/plug in affair.
I know a bunch of the other KL swap guys read this thread.. maybe we need to make a KL swap guide thread... but i'm interested in your thoughts! thanx
 
there is a bunch of info on the other mazda forum and there was even one guy who did an obd 2 kl swap. that could simplify things emission wise but complicate things electrically
 
Hey Teeson, there are a few KL Protege owners who are active on here and are super helpful and will share info. IukekiniProtege (damn it, Justin, why did you have to pick such a hard screen name to type?) is making a website with a ton of info and help on it for the KL swap. I think he's still working on it though. But a thread in the Protege section on KL's wouldn't be a bad idea. For the few of us who have done the swap and can help everyone out and keep the facts from the fiction. I'll see if there isn't already a thread on it and start one if there isn't.

To answer your questions;
Did you cut up your stock harness? Yup. There is actually very little of the Protege harness left in the engine bay.

Did you consider Megasquirt when doing your install? Yup. But at the time I considered it too expensive. (~$650)

Besides the engine/tranny what else did you have to buy?

-KL ECU and VAF/MAF (it depends on if you want to run OBD1 or OBD2 for which ones)
-KL engine harness
-MX-6 radiator and hoses
-air intake piping and filter
-custom exhaust midpipe
-power steering hose and plastic adapter
-adjustable temp fan relay kit
-miscellanious nuts, bolts, wire, solder, heat shrink tubing, etc

But basically, that's what you'll need to get it in and running. You can use the stock KL stuff or you can upgrade parts before you swap like most of us did. Headers, clutch, IM spacers and such. But those will add to the cost.

As far as emissions, I'm not sure how they are in your state. But idealy, you can swap in the KL and ECU and retain your catylitic converter and OBD port/CEL and still be legal. I would think, but I'm not positive. I have emissions here in Ohio but it's only in certain counties. Thankfully my car will be regstered at my girlfriends parents were E-check is not an issue. heh-heh. But I don't know about you swapping an engine, the OBD swap (if you're going to OBD1) and turbo if you will have trouble passing inspections. And swapping the FS-DE would be such a pain. Popping the axles out every year would be enough of a headache for me. heh-heh

Megasquirt would be ideal, or that link you posted (that's acutally really a good deal and I was not hip to that option at all) but as bullshark will tell you, even MS isn't as easy as it sounds. Honestly, I thought I would have the swap done in a week or two. It took me 1-1/2 months of wrenching pretty much every weekend and from 5-8pm every day. It's a lot of work and there are quite a few custom things you'll need to do. Not to scare you away from the swap of course. But I think I'm a pretty mechanically inclined fellow and I needed a lot of help from other members and friends. But I'm also super anal and particular with parts. A lot of parts just bolt right up, but you're bound to hit a few snags as well.
 
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Haha! Nah, a reliable daily driver. Sounds like it needs a new motor which I already know plenty about. The weak link on Milly's are their tranny's and this one had it replaced last year.
 
Mr. Big Bucks I am not. But it's a great deal. I talked to the seller today and am looking at it tonight. If it's not a Millenia S and I don't find anything too wonky with it, I'll buy it. My dad gave me a loan. Then Josh offered to tow it for me back to the Mazda Frat house (PIE). Then I'll have enough money in about a month for a new motor then swap it in and have a badass DD and no car payments. Score! I'm very excite!
 
Lewis7789 said:
Hey Teeson, there are a few KL Protege owners who are active on here and are super helpful and will share info. IukekiniProtege (damn it, Justin, why did you have to pick such a hard screen name to type?) is making a website with a ton of info and help on it for the KL swap. I think he's still working on it though. But a thread in the Protege section on KL's wouldn't be a bad idea. For the few of us who have done the swap and can help everyone out and keep the facts from the fiction. I'll see if there isn't already a thread on it and start one if there isn't.

To answer your questions;
Did you cut up your stock harness? Yup. There is actually very little of the Protege harness left in the engine bay.

Did you consider Megasquirt when doing your install? Yup. But at the time I considered it too expensive. (~$650)

Besides the engine/tranny what else did you have to buy?

-KL ECU and VAF/MAF (it depends on if you want to run OBD1 or OBD2 for which ones)
-KL engine harness
-MX-6 radiator and hoses
-air intake piping and filter
-custom exhaust midpipe
-power steering hose and plastic adapter
-adjustable temp fan relay kit
-miscellanious nuts, bolts, wire, solder, heat shrink tubing, etc

But basically, that's what you'll need to get it in and running. You can use the stock KL stuff or you can upgrade parts before you swap like most of us did. Headers, clutch, IM spacers and such. But those will add to the cost.

As far as emissions, I'm not sure how they are in your state. But idealy, you can swap in the KL and ECU and retain your catylitic converter and OBD port/CEL and still be legal. I would think, but I'm not positive. I have emissions here in Ohio but it's only in certain counties. Thankfully my car will be regstered at my girlfriends parents were E-check is not an issue. heh-heh. But I don't know about you swapping an engine, the OBD swap (if you're going to OBD1) and turbo if you will have trouble passing inspections. And swapping the FS-DE would be such a pain. Popping the axles out every year would be enough of a headache for me. heh-heh

Megasquirt would be ideal, or that link you posted (that's acutally really a good deal and I was not hip to that option at all) but as bullshark will tell you, even MS isn't as easy as it sounds. Honestly, I thought I would have the swap done in a week or two. It took me 1-1/2 months of wrenching pretty much every weekend and from 5-8pm every day. It's a lot of work and there are quite a few custom things you'll need to do. Not to scare you away from the swap of course. But I think I'm a pretty mechanically inclined fellow and I needed a lot of help from other members and friends. But I'm also super anal and particular with parts. A lot of parts just bolt right up, but you're bound to hit a few snags as well.
Click to expand...

Evan, I was 17 and just got back from Hawaii when I joined. I had a cool name keychain that said Iukekini was Justin in Hawaiian, who knows if it really is, but thats why. I thought about seeing if I can have it changed, but I think it might be confusing at this point.

As for the site I am still workign on it, I have the domain bought (KLProtege.com) with hosting too. I just need to really finish up.

It took us 2 weekends and a week(6/7pm-10pm) to get mine done. Evan, I think if the confusion with wiring diagrams was avoided you would have been done quicker. Anyways, I don't see unless you go the full and functioning OBDII KL route that you will be able to pass inspection. I do suggest thinking everything through. I had helped with swaps on Hondas before and many rebuilds on DSMs in the area, but never did anything with a protege. But, its all the same idea. I played out what had top be done over and over again in my head, then formed a good plan. Ran into having the wrong Disty, but that was a easy fix and would have saved 2 days of delay. Basically, check through it everything and make sure u have what you need.

That is a crazy deal on the milly. GET IT!
 
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u talking about the name? if so i figure as much now, its just a goofy souvenir from a wonderful trip.
 
IukekiniProtege said:
As for the site I am still workign on it, I have the domain bought (KLProtege.com) with hosting too. I just need to really finish up.

Anyways, I don't see unless you go the full and functioning OBDII KL route that you will be able to pass inspection.
Click to expand...

I feel your pain, I hate web design lol.

I live in British Columbia Canada, and I think what they do here might be different.
they find your OBD2 scan port (in our case under the hood), they plug in a scan tool. This tool looks for CELs, the VIN, and make model etc. I'm unsure about replacement ECUs, but to pass all this has to add up and have no more than 1 CEL.
Not only would swapping to a OBD1 or early 2 be difficult to wire, you would have to trick the protege ECU into thinking that v6 signals are normal. I have to use the ECU with my vehicles information on it.
Not to mention if I ever get a vehicle inspection, within 10 seconds of popping the hood they'd know something's wrong. BC also has a law saying you cant swap engines that are older than your car.
I think in my case this is the easiest solution, or just move to a place that doesnt require AirCare...

I'm not to worried about stuff like popping the axles, my car's fairly rust free.

Thnx for all the input guys, and Iukekini I hope that your site has a disscussion/forum section
 
it will be unlikely that it will have a forum/discussion. I believe all that can be done here (mazdas247.com) just fine. However, I will have contact info for me and anyone who wants to help out as well.
 
Lewis7789 said:
...The more I think about it, the more I think I should just wait until next year when I'll be tracking the car full time. Then I'll buy an AutoPower roll cage and proper 5/6-point harnesses and do it right.
Click to expand...

Evan,

Go roll bar/cage before that harness bar, they are more fashion than anything. You really shouldn't be running harnesses on anything less than a REAL rollbar, as mentioned before, they can deform/collapse/swivel in an the event of an accident/rollover. So long as you're without a rollbar, stick with the stock belts. Also mentioned elsewhere is the cg-lock, thats a pretty nifty tool to improve the restraint of the stock 3pt belts.

Track time is fun regardless of what your in, run your P5 I think that's great! If mine is road worthy I may make the trek to summit point in november. Seems like the perfect track car, plenty of room to haul another set of stickies, a pavilion, cooler, tools, etc. HPDE's are great fun if you aren't into competition. I do it more because I enjoy it, not to prove anything. Now that you're KL powered, the P5 should be a hoot!
 
OUP! guess my comments can be taken out of context. I have HSAX and that was like no investment at all just having fun with the car. But I meant to say (cause I had no idea till this first year of real W2W racing) that racing by its self is expensive. Its not necessarily a deturent but a note to start saving now for next year. It cost me 500 bucks in fees gas food and stickers and what not just to get my license. And like every single day weekend is like 350. I had no idea. I saved up a good bit of money to help me along the season, but went and spent it on the trailer like a jerk. So now I have to put some of this cost onto a C.C. I make s*** for money, so if I can do it anyone can.

Oh, and yeah don't race what you wouldn't mind loosing. It dose not seem to happen much, but I mean it could happen at any time. But only love for ya man. Good Luck!!!
 
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