Lewis7789 2002 Protege5 build thread (tons of pics)

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im not sure about the curve neck but with the straight neck using the outlaw spacer you have to make sure the throttle body is off or it will hit the master cylinder. once again i am not sure about the curve neck clearance but just keep an eye out. and 1 more thing. i love the paint job it looks sick
 
Glad you went that route with the Valve covers..they look great!

The curve neck should not have clearance issues with the spacer on it.

As for knowing which year the motor is from..it is 95+. When you order parts for it you should be able to order parts for a '95 Millenia. That way for gaskets and such you will get square port gaskets. Everything else externally is the same between the USDM and JDM Millenia motor, so just get parts for a '95 Millenia. Electrical parts will depend on which year harness you use..
 
Thanks guys. I knew the spacers would clear the master cylinder. One of the reasons why I got the curve neck in the first place, so I wouldn't have to modify the throttle butterfly or relocated my battery and can run the TB spacer.

So if all the Millenia motors are 95+ I'm assuming I have an OBD1 motor since it has a distributor, right?

I was looking at the 94 PGT wiring harness last night side-by-side with the JDM harness. A lot of the connectors are the same, just different colors for the wires. Do the KL's only use one O2 sensor? I see where one was cut on the JDM harness but didn't see another one. I didn't even think about the O2 sensors until I was researching headers. I'll have to do more research for O2 sensors and see if maybe one of the Protege sensors would work. If not, I'm not too worried about buying a new sensor.
 
I am not sure, honestly. I would assume they are either all OBD2, or the '95 only is OBD1. The Millenia always had a distributor, so that means nothing. The only KL powered car that got a coil-pack is the 98-2002 Mazda 626 v6. The millenia had the different air-flow meter, but never had solid lifters or a coil pack.

93-95 had 2 02 sensors. 96 had 4 (precats). 97 had either 3 or 4, I forget..The 94, should be able to utilize the conversion to a one-wire 02 sensor..I know there is a write-up on PT about that.
 
Holy crap. 4 O2 sensors? Are you sure? I don't think I've worked on a car that had more than 2 O2 sensors... Looks like I've got more research to do... I also have to find out if the Millenia has a VAF or a MAF and then find out which part number will work with my KLK1 ECU.

edit- I think you're talking about the number of wires per sensor, not how many sensors. My bad. I found that one-wire conversion post. Bullshark posted a link in the How-To thread here on 247.
 
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No, I am talking about the number of sensors, 700% sure, I promise you.

My '96 had 4 02 sensors. Two upstream of the precats and two downstream to monitor the efficiency of the pre-cats.

My Maxima has 4 of them also, fwiw.

As for the millenia air-flow meter conversion..there are a couple of people who have recently done it on PT..search for it. WhiteDart is a PT user who successfully did it.
 
yea a v6 always has 2 banks, and if there are pre-cats like how the protege's are setup, then there SHOULD be 4 o2 sensors
2 before, 2 after on each side of the engine
 
Dayum... So I'm looking at $400 in new O2 sensors. boo. haha Well, thanks for the info, guys. I'll have to track down where they plug in the harness and look up some headers to see where they plug into the bungs and figure out a way for them to get welded into the exhaust. I'm planning on running catless so I'll probably have to do the non-fouler trick for the rear O2 sensors. Or maybe just run one rear sensor and tap the wires so the ECU thinks it's running two sensors? Hmmm... Well more research is needed. I'll look into all that this weekend. And thanks for the conversion tip, JK. I'll look into that as well. I've already got a KL36 ECU and JE-50 VAF that I bought for $120 even before I had the motor. But now I've got the KLK1 JDM ECU that came with the Milly motor so I plan on using that with a MAF, IF it's a reliable setup.
 
Or you could create a single turbo setup and put one after the turbo and after the main cat...

... just sayin'.
 
I still have the stock mani and exhaust on my KL on the stand if you need pics (with harness still on too). If you need pics but they go 2 on each bank and before and after pre cat. just non fouler the 2 downstream ones

Hell if you want my O2s let me know i can get the proper pics and put them fs. I will be selling the whole motor now since it is useless to me.
 
Thanks very much, Jon. I'm still researching the O2 setup. Apparently Justin with the KLZE swapped Protege is just running two O2 sensors (from an MX-6), one in each header.

I'll have to dig around on the PGT harness and see what I've got there. I know it's a 94 harness so it's OBD1. I will tackle all of that tomorrow. I might hit you up for the O2 sensors. Thanks!

Good news is I think I'm actually "done" with the motor. It's all buttoned up and ready. I got the thermal spacers, and new spark plugs and belts. I just need to wait untill after the holidays to buy the clutch and lightweight flywheel and headers. So I think I'll have all the parts ready by late January. Then I hope to have the harness and wiring all figured out and ready for the swap in the spring.

IMG_20101218_163800.jpg
 
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Fidanza. I don't want to have to pull the tranny for a loooooooooong time. heh-heh.
 
Lewis did you clean the IAC real good? I have ran into problems with them twice so far but i got them down to a science now. What a temperamental piece of crap. LOL
 
Jon, I didn't clean that... I cleaned the TB really well but didn't know about the IAC's until you mentioned it. Then I researched it and it seems like a good thing to clean while it's easily accessable. Want to hook me up with a How-To or step-by-step, buddy?

It sounds like the IAC is like the EGR on Protege's. Just something you should clean every year.
 
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