gone_fishin
Member
- :
- One of a Kind '99
So, I created this thread to show the msp community (that I love so much) my project that I've been working on for the past four weeks or so.
As seen under my forum name, I own a 1999 protege ES (1.8 liter) 5 speed. About a month ago I decided to begin the entire mazdaspeed underhood conversion. This wasn't just a motor swap, it was basically the entire 2003 mazdaspeed protege front end which gives you an idea of the ammount of work it's taken. Some of you might know my story-- I purchased this MSP front-end with the intention of doing this project but time contraints and a lot of other things got in the way. After trying to sell it for a time and debating with myself, I finally decided that there will always be excuses and to just do it. Listed below is everything that was purchased for the swap, and everything that is in the process of being swapped in. The front end clip had approximately 18,000 miles on it and was in excellent condition.
What was Purchased:
-MSP 2.0 Engine (with engine cover), intake mani, intake piping and MAF
-MSP 5 Speed Manual Transmission
-MSP Limited Slip Differential
-D & P side Drive Axles
-Callaway Turbo Manifold with Garrett turbo assem
-Callaway Downpipes (both S and J pipes)
-Stock Intercooler with all intercooler lines and piping
-ECU and ECU wiring harness
-Front Suspension-- tokicos with RB springs (including front sway bar)
-Stock Motormounts
-Shifter Assembly and Shifter Linkages
-Driver side and passenger side brake assemblies-- includes spindles,
ABS sensors, brake lines, hub assemblies, rotors, and calipers
-Also including MSP Sparco Gas, Clutch, and Brake Pedal Assemblies
-MSP Subframe
After doing a lot of research, I think I might be one of only two guys in the north american mazda community that have done this swap. It was definately uncharted territory. It's come a long way since it was started and it's been a headache would be an understatement. However, the build is on its way to completion and that makes it all worth the while. This build has presented so many unique problems and obstacles-- we've had to fabricate mounts, brackets, and a driver side axle, and we are currently in the process of dealing with all the electrical nuances. Everything above will be used, even the front suspension.
The Headaches
There have been plenty of discrepancies along the way between the 99 ES and the 03 MSP-- the entire fuel delivery system, the entire exhaust system, the entire cooling system, the spindle and hub assembly differences, the ECU and the majority of the electrical/wiring harnesses.
The Resolutions
To address the fuel system discrepancies, the mazdaspeed protege fuel tank was ordered (with the msp internal pump) and the fuel lines. The msp fuel tank however, was slightly different in it's design, so the 1.8 fuel tank was used and the msp fuel pumps and lines swapped in to keep it as clean as possible. To address the exhaust system differences, I ordered and dropped in the GHL full 3'' turboback exhaust. After installation, the downpipe was found to be touching the oil pan, so it had to be heated with a blowtorch and coaxed off the oil pan (no kinks or creases were made). The spindle and hub assembly conversion was an absolute nightmare. Unfortunately the 99 ES came from the factory with drum rears and thus 4 bolt hubs. What we finally decided to do was remove the 99 spindles and hub assemblies were from the 99 subframe (still on their lower suspension arms) and re-mount them to the MSP subframe. This allowed me to keep the 4 bolt hubs up front-- otherwise it would have been 5 up front and 4 in the rear. The splining on the driver side axle was giving us considerable difficulty, so we ended up fabricating and splining an entire new axle for it. Side motor mounts also had to be fabricated from scratch because the bolt pattern on the MSP side mounts differ from the bolt pattern on the 99 frame.
We also ran into some problems with the cooling system. The normally aspirated third generation proteges have radiators that span the entire distance between the headlights within the engine bay. The fans additionally span this distance. To accomodate for the MSP SMIC, the radiator and the radiator fans on the MSP were designed much less wide. So, a stock MSP radiator and fans were purchased to make room for the stock SMIC. That heat-soaked stock piece of crap will be scrapped though, and I'll be installing the Hi-boost front mounted intercooler for the msp relatively soon.
The Injen cold air intake system will also need to be retrofitted to fit, which will involve some cutting and redesigning. Why not get the Injen CAI for the MSP? To be completely truthful I really don't feel like spending another 200 some dollars, and I'm sure with some modification the intake for my 99 will function/fit just the same.
What still needs to be addressed are the electrical and wiring nuances-- there are tons, and they all pertain to the tach and gauges. It's going to take a lot of wiring diagrams and some soldering, but we'll get it done.
Current Modifications to the Build
-AWR 95 durometer motor mounts (front and back),
-Custom fabricated side motor mounts
-Full GHL 3'' turboback exhaust
-Injen Cold Air Intake
-B&M Short Shifter
-Power Slot Slotted Rotors
-Autometer water, oil, and voltage gauges
-Bridgestone Potenza Z rated tires.
Modifications Soon to Come
-Hi-boost FMIC
-SU Intake Mani
-UR UDP
-Intake and Exhaust cams-- (see twighlightprotege's GB thread)
-UR stage 2 clutch and UR flywheel
-Boost Sciences MBC
-Tein Coilovers (non EDFC, all 4 corners)
-Boost and Wideband AF gauges
I'm planning on keeping the boost at stock levels, or possibly 1-2 pounds over stock. I have no plans to make any modifications to the exterior-- I'd like to keep it completely stock in appearance.
The project isn't complete but the engine is cranking and because of this, I wanted to snap some pictures tonight and take some video for you all. I hope you enjoy. The engine bay (and car) is dirty as s*** and I apologize, but it's been in the shop for a while. As soon as it's finished it will all be cleaned up. Enjoy!
This address links to some pictures of the front end clip originally before it was swapped in. It will look just as clean as this once the build is completed.
To The Bottom...
http://www.msprotege.com/forum/showthread.php?t=117789&page=6&highlight=mazdaspeed+changeover
Here are the pictures and vids that were taken tonight. (Note: the whining noise on the first startup is the power steering pump-- that will be fixed tomorrow. The SMIC or the intake have not been installed yet so esentially right now it's n/a until they are. The pictures of the engine and tranny on the come-along are what was taken out.)
Giving it some throttle.
Cranking the Engine.
(the whining noise is the power steering pump-- it will be fixed tomorrow)
The Old Setup
Another Shot of the Old Setup
The GHL Downpipes and Exhaust System
One of the Fabricated Side Motormounts
As seen under my forum name, I own a 1999 protege ES (1.8 liter) 5 speed. About a month ago I decided to begin the entire mazdaspeed underhood conversion. This wasn't just a motor swap, it was basically the entire 2003 mazdaspeed protege front end which gives you an idea of the ammount of work it's taken. Some of you might know my story-- I purchased this MSP front-end with the intention of doing this project but time contraints and a lot of other things got in the way. After trying to sell it for a time and debating with myself, I finally decided that there will always be excuses and to just do it. Listed below is everything that was purchased for the swap, and everything that is in the process of being swapped in. The front end clip had approximately 18,000 miles on it and was in excellent condition.
What was Purchased:
-MSP 2.0 Engine (with engine cover), intake mani, intake piping and MAF
-MSP 5 Speed Manual Transmission
-MSP Limited Slip Differential
-D & P side Drive Axles
-Callaway Turbo Manifold with Garrett turbo assem
-Callaway Downpipes (both S and J pipes)
-Stock Intercooler with all intercooler lines and piping
-ECU and ECU wiring harness
-Front Suspension-- tokicos with RB springs (including front sway bar)
-Stock Motormounts
-Shifter Assembly and Shifter Linkages
-Driver side and passenger side brake assemblies-- includes spindles,
ABS sensors, brake lines, hub assemblies, rotors, and calipers
-Also including MSP Sparco Gas, Clutch, and Brake Pedal Assemblies
-MSP Subframe
After doing a lot of research, I think I might be one of only two guys in the north american mazda community that have done this swap. It was definately uncharted territory. It's come a long way since it was started and it's been a headache would be an understatement. However, the build is on its way to completion and that makes it all worth the while. This build has presented so many unique problems and obstacles-- we've had to fabricate mounts, brackets, and a driver side axle, and we are currently in the process of dealing with all the electrical nuances. Everything above will be used, even the front suspension.
The Headaches
There have been plenty of discrepancies along the way between the 99 ES and the 03 MSP-- the entire fuel delivery system, the entire exhaust system, the entire cooling system, the spindle and hub assembly differences, the ECU and the majority of the electrical/wiring harnesses.
The Resolutions
To address the fuel system discrepancies, the mazdaspeed protege fuel tank was ordered (with the msp internal pump) and the fuel lines. The msp fuel tank however, was slightly different in it's design, so the 1.8 fuel tank was used and the msp fuel pumps and lines swapped in to keep it as clean as possible. To address the exhaust system differences, I ordered and dropped in the GHL full 3'' turboback exhaust. After installation, the downpipe was found to be touching the oil pan, so it had to be heated with a blowtorch and coaxed off the oil pan (no kinks or creases were made). The spindle and hub assembly conversion was an absolute nightmare. Unfortunately the 99 ES came from the factory with drum rears and thus 4 bolt hubs. What we finally decided to do was remove the 99 spindles and hub assemblies were from the 99 subframe (still on their lower suspension arms) and re-mount them to the MSP subframe. This allowed me to keep the 4 bolt hubs up front-- otherwise it would have been 5 up front and 4 in the rear. The splining on the driver side axle was giving us considerable difficulty, so we ended up fabricating and splining an entire new axle for it. Side motor mounts also had to be fabricated from scratch because the bolt pattern on the MSP side mounts differ from the bolt pattern on the 99 frame.
We also ran into some problems with the cooling system. The normally aspirated third generation proteges have radiators that span the entire distance between the headlights within the engine bay. The fans additionally span this distance. To accomodate for the MSP SMIC, the radiator and the radiator fans on the MSP were designed much less wide. So, a stock MSP radiator and fans were purchased to make room for the stock SMIC. That heat-soaked stock piece of crap will be scrapped though, and I'll be installing the Hi-boost front mounted intercooler for the msp relatively soon.
The Injen cold air intake system will also need to be retrofitted to fit, which will involve some cutting and redesigning. Why not get the Injen CAI for the MSP? To be completely truthful I really don't feel like spending another 200 some dollars, and I'm sure with some modification the intake for my 99 will function/fit just the same.
What still needs to be addressed are the electrical and wiring nuances-- there are tons, and they all pertain to the tach and gauges. It's going to take a lot of wiring diagrams and some soldering, but we'll get it done.
Current Modifications to the Build
-AWR 95 durometer motor mounts (front and back),
-Custom fabricated side motor mounts
-Full GHL 3'' turboback exhaust
-Injen Cold Air Intake
-B&M Short Shifter
-Power Slot Slotted Rotors
-Autometer water, oil, and voltage gauges
-Bridgestone Potenza Z rated tires.
Modifications Soon to Come
-Hi-boost FMIC
-SU Intake Mani
-UR UDP
-Intake and Exhaust cams-- (see twighlightprotege's GB thread)
-UR stage 2 clutch and UR flywheel
-Boost Sciences MBC
-Tein Coilovers (non EDFC, all 4 corners)
-Boost and Wideband AF gauges
I'm planning on keeping the boost at stock levels, or possibly 1-2 pounds over stock. I have no plans to make any modifications to the exterior-- I'd like to keep it completely stock in appearance.
The project isn't complete but the engine is cranking and because of this, I wanted to snap some pictures tonight and take some video for you all. I hope you enjoy. The engine bay (and car) is dirty as s*** and I apologize, but it's been in the shop for a while. As soon as it's finished it will all be cleaned up. Enjoy!
This address links to some pictures of the front end clip originally before it was swapped in. It will look just as clean as this once the build is completed.
To The Bottom...
http://www.msprotege.com/forum/showthread.php?t=117789&page=6&highlight=mazdaspeed+changeover
Here are the pictures and vids that were taken tonight. (Note: the whining noise on the first startup is the power steering pump-- that will be fixed tomorrow. The SMIC or the intake have not been installed yet so esentially right now it's n/a until they are. The pictures of the engine and tranny on the come-along are what was taken out.)
Giving it some throttle.
Cranking the Engine.
(the whining noise is the power steering pump-- it will be fixed tomorrow)
The Old Setup
Another Shot of the Old Setup
The GHL Downpipes and Exhaust System
One of the Fabricated Side Motormounts
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