Lewis7789 2002 Protege5 build thread (tons of pics)

[Lewis7789]

I'll ask TT to bring me over a roll then you'll be down to 199 rolls. haha

So I've been pondering the radiator issue. I'm thinking of just buying an OEM style radiator online or from Autozone (~$100) for the MX-6 and adding 1 or 2 slim fans and a coolant overflow tank. In theory that's all I would need, right? The bottom mounting brackets are the only thing I would need to worry about. I would just rather not buy a used radiator. You just never know if they have problems or cracks/holes.

 

[PrinceValorum]

I have a PGT rad that may or may not have cooked noodles and rice inside it that I'm willing to let go...

Keep your overflow jug. I know the 626 are known to have them crack very easily (with age), and I'm guessing the other models do, too.

 

[HKPRO5]

Or you could always use an aftermarket overflow tank. They are usually not that expensive. Signature sound has some nice ones.

 

[Lewis7789]

Yeah, I think I'll pass on the cooked rice radiator, Wes. haha. And I'm buying Fishy's SignatureSound overflow tank when he's ready to swap it out.

 

[fishdonotbounce]

Evan, I'm glad I saw your post cause I gotta talk to Chris about the bracket for the overflow tank so that I can get mine off the car. I'll let you know when I do.

Also, if you get a radiator from a parts place, get it from advance. Make sure it has their lifetime warranty. I already swapped one out because I had forgotten to connect the main fan over the winter and then in the spring it got too hot and started leaking at the top cause of all the heat. Once I got my new one and swapped it it and connected the main fan, all was good. One of those rads with two slim fans that move a good amount of air should be more than enough. The warranty is extremely easy to do too. I had even lost my receipt and they looked it up in the computer. I went in, paid for the radiator replacement, swapped it in, brought back the old one and got my money back no questions asked.

Good luck with the rest of the build man.

 

[hat1018]

Evan don't be foolish, buy a new rad the extra cash is worth the piece of mind. 2 fans fo sho, " an ounce of prevention...." you know what I mean.

 

[Lewis7789]

Thanks Ivan. I was going to politely remind you about the tank soon anyway, heh-heh.

Larry, the original plan was to buy a new radiator anyway. And I remember Ivan told me the story about his radiator from Advance so I'll keep that in mind.

I was talking to Phen last night and his friend has his own shop (Nameless Performance) in Washington and could fabricate me an aluminum radiator with the right inlet/outlet orientation for the KL and the right mounting tabs for the Protege (since the V6 radiators need to be modified to fit) for around $400. I'm debating if that will be overkill for my build or not... $400+$100 for fans+$50 for the overflow tank = $550 or $100 for an OEM style radiator + fans and tank = $250. Hmmmm...

 

[JKPgt96]

It is very much so overkill. But, most anyone that puts an aftermarket radiator in a KL powered car doesn't need it. Its up to you whether or not you want to do it or not..just because it is overkill doesn't mean you shouldn't do it. Just be certain you will have room for fans and a thicker core. The stock Radiator is only ~1 inch thick, and I know the one I have is ~3 inches thick, and with the Hothost style headers my stock fans were up against the headers. Now when I put in my pacesetter headers I had a lot more room, because they turn quicker (but more gradually) out of the exhaust port.

 

[PrinceValorum]

If I was going to beef up part of the KL, it would be the oil system. You don't even rev your engine very high, you won't be making much heat, Evan.

 

[jonridinhi]

finally made it over here....

If you plan on going a/c less you can put 2 push fans in front of the radiator. and then you will still have room for thick core radiator and a 4" thick IC when ever you make it that far. I have already measured that one out for you. SUBBIN...

Ohhh and here is the KL that me and PRD are building.....

 

[Sport23]

^^ sounds good man. Every day makes me want a KL P5 even more!

 

[HKPRO5]

Was wondering what are you going to use for ECU I seen a jdm klZE ECU but is that all? Figuring out what I would need for a swap. Do you have a definitive part lis of things that I would have to obtain?

Thanks

 

[Lewis7789]

Thanks for the info, Jon. And for the video link. Fire is coooool.

HK, I have a KLK1 (I believe is the part number on the ECU that came with my motor) and a KL36, both are JDM. I'm pretty sure either a KL31 or KL36 ECU will work but you need the JE-50 vaf to go with those. I'm going to try both ECU's at the Dyno day in the spring and see which is better for my application.

Very productive day today. I work super freaking slow and label the crap out of everything so it took my friend Pablo and I about8 hours to change the head gaskets (with a lunch break and a trip to Autoze and Home Depot). Good news is that they were not blown and everything looks pretty good inside. I totally forgot to order a new timing belt so I'll order that tonight and put that on this week. And my Outlaw spacers should be in this week then I can finally put the valve covers and intake mani back on so the motor will be sealed up again. I've got a towel and piece of plastic over the heads right now.

Pics;
Here's Pablo removing the old gasket material. I bought a "gasket remover" from Autozone that was a piece of crap and would just scratch up the surface. So 4 Dremel polishing disks later, the heads were nice and clean.

The cams removed and heads ready to be pulled off.

Eww...

Much better.

 

[jonridinhi]

PRDracing or I will start a thread for the build of the probe. Same thing there, that head gasket was a royal PIA to prep for. We did a compression test today and the results we astonishing for what we did. And the funny thing is we got the same pics....

And by the way are you going to try the kl47 ecu or not?

and the fire and poping are from an open dump after the header to test run and the distrib. not being timed perfectly to the engine. All those issues are now solved.

 

[THE Phen]

Hey Evan, I was talking with Jason. We think he can do it... but like was mentioned earlier... it's probably not needed.


Oh, and I had a gasket scraper. Gasket scraper + brake cleaner = win.

 

[jonridinhi]

We found purple power + brass bristled brush + steel wool = win for us! Still a pain any way you looked at it. Atleast yours is out of the car.

 

[Lewis7789]

Haha! Yeah, we kept saying "Damn, it's a good thing this isn't in the car...". I just used some Seafoam on a rag afterwards to clean up the heads/block and on the piston tops. I love that stuff. I'm going to clean the ports with some Seafoam too. I was just worn out yesterday. It took Pablo and I about 8 hours just to replace the headgaskets. When the motor is not in the car and things don't have to be rushed and I can always finish the job tomorrow, there's no need to hurry.

I also got the block ready for the Unorthodox Underdrive pulley by cutting off the lip on the motor. I mocked it up and it looks good. Just waiting for the timing belt and accessory belts to get here from RockAuto.

 

[Lewis7789]

PRDracing or I will start a thread for the build of the probe. Same thing there, that head gasket was a royal PIA to prep for. We did a compression test today and the results we astonishing for what we did. And the funny thing is we got the same pics....

And by the way are you going to try the kl47 ecu or not?

and the fire and poping are from an open dump after the header to test run and the distrib. not being timed perfectly to the engine. All those issues are now solved.

What's PRDracing? And I'm assuming the compression test was good? I hope... haha. You should do a build thread, it's really helpful for other cats to find hard facts and first hand accounts. Not just "well I read this from another member...".

What's a KL47 ECU from? I figured the KLK1 (I'm pretty sure that's what it is but the numbers are faded) that came with the motor would be best.

 

[jonridinhi]

What's PRDracing? And I'm assuming the compression test was good? I hope... haha. You should do a build thread, it's really helpful for other cats to find hard facts and first hand accounts. Not just "well I read this from another member...".

What's a KL47 ECU from? I figured the KLK1 (I'm pretty sure that's what it is but the numbers are faded) that came with the motor would be best.

PRD is dereks screen name aka owner of the probe. LOL kl47 is the milly ecu and then you can run an actual MAF. Just my original plans but now i might just sell the engine and MP3 and move on. But i will make sure the Probe build happens Yeah tested good and we found a faulty injector. replaced it and now she purrs

 

[Lewis7789]

Cool man, I'll look him up. I researched the KL47 after I posted and saw it's a 95 and older Milly ECU thus OBD2 and pressumed you were talking about a MAF conversion. Honestly, I think I'm going to hold off on the MAF conversion until after I have the motor running correctly. I don't want to change to many things around and make it even harder to troubleshoot when it is ready to be swapped. But thanks for the info, I bookmarked a How-To I found for the conversion.