Lewis7789 2002 Protege5 build thread (tons of pics)

[bullshark524]

^^^how did you get into my mind???^^^

 

[PrinceValorum]

My ideal "house" would be a kitchen, bathroom,& 2 bedrooms attached to a 3 car garage! Oh yes heated concrete floor, insulated and drywalled, radiant heat, tons of lights, a kick as work bench, def gonna have a lift maybe 2, a couple of recliners a sofa, big screen T.V, and of course a beer fridge. That should just about cover it. Man cave with bedrooms haha!

That would be friggin awesome. There's a house near me, it's got a 3 car detached garage, the left side is a double door, and it's got a car port/awning that hangs out long enough to cover two cars in the driveway and then another exposed garage door on the right side. I'd love to be able to wrench semi-outside without worrying about having to pack up everything if it starts raining. Or snowing, knowing Ohio.

That's weird, Evan. I remember those bolts being hella long, and the little mix up with the mounts (oops..). Are you going to have to take the timing belt back off, too?

 

[bullshark524]

car ports are awesome i love mine but you definatley need something with 4 walls for winter

 

[Lewis7789]

I don't think the timing belt has to come off. Just the belts and a few other bits and pieces. Josh is going to pop the Protege one off for me and I'll put it on Saturday. But with the timing belt cover off, I'd like to triple check the timing just in case anyway. No worries. So looks like we might start a little later saturday if you want to sleep in. heh-heh

But yes, I'm very lucky my old tranny and an FS-DE are just 20mins away for silly oversights I keep doing and thankfully Josh is cool with me hounding him for parts. whew!

 

[Josue6WGN]

Hey, one hand washes the other!!

And there was a PERFECT place around the corner from my parent's house a while ago, but I'm sure it's sold by now. 1600sqft (7 car) barn, heated and air conditioned, additional 1200sqft work area, 1000sqft 1 bd 1.5ba loft above....all on 20 acres with a pond, plenty of room to build a house should you grow out of the loft!

 

[hat1018]

^that

 

[Joost27]

Bullocks. I already hit a snag. heh-heh

It looks like the passenger motor mount bolts are a lot longer than the ZE counterpart. My Protege MM won't tighten down onto the engine side of the bolts, if that makes sense. I supposed I could fab up some metal bushings or use a die to thread them down but Josh is going to check out the bolts on his broken FS-DE and maybe I can swap them out. Of course I'll have to take the belts off, timing cover and all that jazz to get to the bolts but it could be worse. At least I spotted in now instead of Saturday when the motor is supposed to be in.

Here's what I'm talking about. My "Milly" motor bolts are super long and not threaded all the way down.

And here's Justins ZE bolts.

Crappy, yeah my bolt lengths are perfect for the protege mount. Almost identical to the FP and im sure the FS. These are little bits of info I am gathering for the website (which i am still working on, taking forever with my busy schedule and preparations for the meets/shows this year on top of finding a house).

 

[Lewis7789]

Yeah, I'm just trying to post up as much info as possible in this thread (with pics) for future reference for other potential KL swaps.

Thankfully, Josh is pulling his mount off his old FS and I can put it on the KL tomorrow morning.

 

[Joost27]

Hopefully the bolt holes line up on the block. Be sure to take pictures of that

 

[Lewis7789]

Will do. If the bolt holes don't line up I bought a tap/die set a month ago for just such occasions. Or absolute worse care scenario, I'll have to fab up some spacers from Home Depot Racing.

 

[HKPRO5]

Oh? Where do I apply for HDR sponsorship? lol

So will you have a definitive parts list when you are done? (for potential swaps?)

 

[Joost27]

Oh? Where do I apply for HDR sponsorship? lol

So will you have a definitive parts list when you are done? (for potential swaps?)

HKPRO5,
Is that direct at me? if so, the parts list in my thread is pretty definitive. However, a complete list will be hard since you can go many different routes as far as wiring, which motors, transmission, OBDI or OBDII or Megasquirt or similar. However to physically get the motor in its all essentially the same except we now know the millenia has a different mount bracket than the ZE and the US DE.

Evan,
I dont think the spacer idea is going to work though. With Spacers unless the "deck" the studs come through is lower than the normal ZE/DE then the spacers will set that side of the motor down lower and make it slant which cant be good on the other mounts, and axles.

 

[THE Phen]

Evan,
I dont think the spacer idea is going to work though. With Spacers unless the "deck" the studs come through is lower than the normal ZE/DE then the spacers will set that side of the motor down lower and make it slant which cant be good on the other mounts, and axles.

That popped into my head as well. I was picturing it, but couldn't think of a way to word it. Haha.

 

[03zoomzoom]

seems like you should be able to fab up some sort of spacer to work. is the motor mount too low or too high?

 

[Lewis7789]

Good call, spacers are not a good idea. I'll get the FS bracket tonight and pray to baby Jesus they bolt up. If not, I'll just use a die to thread the rest of the bolts down. Looking at the two Mazda manuals for the Protege and Milly don't look like they are anything different so I don't know why the bolts are so much longer on the Milly. Guess I'll find out tomorrow morning.

 

[Joost27]

well his problem right now are the studs are not threaded far enough and the bracket that comes off the protege body mount is too thin to take up that space, unless the spacers were placed on top of the bracket and went between the protege mount and the nuts threaded on. Which, come to think of it, might have been what he meant to begin with for spacers...

 

[03zoomzoom]

Yeah, option #2 is the way to go. I see option #1 snapping the bolt in about 5 seconds.

 

[Lewis7789]

Thanks for the diagrams, Justin. #2 is mos def the way to go, assuming the motor is level. I already got the motor bracket off and took pics. Hopefully Josh will be able to bring the other bracket tonight and I can at least eyeball them so I can sleep tonight. And I checked the timing about 5 more times. heh-heh. I'm paranoid about the timing but everything looks good.

Justin, while I've got you in here, I was reading in your thread about your fuel lines. I've got two harlines running all the way down to the rear motor mount. They still have the clamps on them so I was thinking of just cutting my Protege fuel lines and clamping them up to the hardlines near the motor mount. Is that what you did too or is the ZE different?

 

[Joost27]

similar to what i did, but because the protege lines are rubber with a nylon insert they dont clamp well. So I disconnected them from the hard lines by the firewall and used i believe 3/8" fuel line and slid them over the protege hard lines, clamped them and then connected them to the v6 hard lines. So basically replace the harder rubber/nylon lines the protege comes with soft rubber fuel line from the auto parts store.

 

[Lewis7789]

Bullocks. The Protege mount bracket isn't even close. But thank you, Josh, for taking it off and bring it with you.

But the bolts are threaded into the bracket. There might be a slim chance I can just swap them out. But they are probably really stuck in there well. So looks like I may make a run to HD for a die. Or maybe Napa or a local machine shop can do it for me. I would hate to buy a die just to use it once.

Once again, I shoulda bought a ZE...