New Owner, have some work to do

[paper1122]

Thanks for the heads up on the VICS, I'll give the dealer a call to see if the recall was done.

I installed the EGR valve tonight, it kicked my butt! I had planned on getting a lot more done tonight. The canadian EGR is bigger by just enough to make the install a PITA. I was very thankful for the install writeup I found on here. I guess tomorrow night the goal will be to get the pass side motor mount (which the part I received looks slightly different than what is currently in the car, though based on a quick look I think everything will line up), radiator hooked up and the battery and air box reinstalled. I think I can still hit my goal of being up and running by the weekend.

The new HD radio showed up today, but the dash kit was broken, within minutes after getting off the phone with crutchfield a new one had already been shipped!

A little dissapointing as I'd hoped to be further along today but all-in-all the project is moving along nicely.

I also setup the tint guy to come tint the windows for the week before Christmas.

 

[paper1122]

Well I had fun this evening.
Somehow I ordered the wrong passenger side motor mount, I'll end up taking a bath on shipping, but at least it is the one that is easy to get to. I installed the radiator, air box, battery, etc. I filled up the system with distilled water and noticed a leak. The thermostat seal managed to squeeze out. The seal (not gasket) was not reusable. So I've spent the past hour and a half trying to locate the part. Here is where the fun part comes in. Stant only lists the part as going up to 02, not 03, so when you search anywhere it doesn't come up until you switch to an 02. Luckily I found the part, in-stock, at my local NAPA so I am sending the wife there tomorrow to pick up the seal, well actually 3 in the event I mess up another one. The dissapointing thing is that we are supposed to get rain tomorrow and I was hoping to have been able to move the car into the garage to finish it up. I didn't want to move the S2000 out of the garage when I first started working on it so I've had to do all the work in the driveway since the car really shouldn't be run without coolant. Now that my evening is shot and the car still isn't running I think I might go have a drink.
The good news is, assuming the part works (sending the thermostat and old seal with the wife) and I don't have any other issues AND the rain holds off tomorrow I should have it running tomorrow evening.

 

[paper1122]

Ok so last night:
The o-ring for the thermostat worked great, the biggest difference between it and the factory part is there was no bump on the o-ring so you just have to match the jiggle pin up with the indent on the thermostat housing. Put everything back together, flushed the system and ran it for a while. Then I opened the drain plug and ran the car while feeding in distilled water to make sure all of the flush was out of the system. I filled it up with coolant and let it run, the only issue I had was trying to "burp" the car, I ended up having to put it on an incline to get the air out.

I also attempted to install the new radio, the issue is, I can't get the old one out. I believe the brackets on the side of the radio must be damaged in some way because the removal tools aren't working, I've never had an issue using the removal tools before on any of my Ford's. Any idea's?

Today is detail day, once I get it all shined up I'll post a few pictures.

Remaining work items:
Cut masonite for hatch area and attach carpet
Window tint
Install radio
Passenger side motor mount
Allignment
Register the car

 

[paper1122]

Detailed the car today, managed to get the smaller scratches out, the Adam's products plus a Porter Cable work wonders. Also detailed the Acura to get it ready to sell. Definately making some significant progress. Hopefully I can figure out how to get the old radio out tomorrow, plus I'd like to take care of the hatch carpet.

 

[KMac]

Getting the old radio out is pretty easy if you have the right pulling tool. Ford radio removal tool 4 pieces of bent wire with notches basically. Most packages only come with 2 pieces so you'll need 4 because its a double din. I made mine out of wire hanger with a little notch on each end. I haven't looked to see if there is a how-to yet.

http://www.ebay.com/itm/02-03-MAZDA...ies&vxp=mtr&hash=item5ad2cbf03a#ht_853wt_1139

 

[paper1122]

The problem I had was the tabs on the radio were bent out to the point where when you stuck the tools in they slid under the tab instead of over. I ended up gaining access so the sides of the radio by removing some the glovebox and a panel on the driver side. Once I did this I was able to push in the tabs and the unit slid right out.
The new radio sounds so much better. It is the cheapest JVC HD radio and it is many times better than the stock HU. The wife is very pleased.

I got the masonite cut for the rear hatch but I haven't attached the carpet to it yet. I sort of ran out of steam today and may not do any more work until tomorrow.

 

[paper1122]

The last motor mount is in, that sure did make a difference. I went ahead and ordered new A/C and Alt belts despite the ones on there being nearly brand new. I just can't get rid of the squeak and if I am going to bother going through the process of re-tensioning I may as well make sure the belts are good. I ordered Gates belts and a tension gauge. I should have the parts on Friday so I'll be doing the work this weekend.

Work still to be done:
Carpet the hatch floor pieces I made
Install new silverstar bulbs upon arrival
Install new yellow foglight bulbs upon arrival
Install K&N drop in filter upon arrival
Window Tint (setup for next Tues)
Alignment
Install new belts

I really can't think of anything else it needs

At this point I am turning the car over to my wife to start driving.

The one project I might take on, possibly this weekend, is painting the rims. The silver paint is not good on them, I was thinking of going with the duplicolor graphite color since the car is silver, I think the contrast would be nice.

My impressions from driving the car this week:
Slow, I mean really slow. I know I am spoiled, my Truck has nearly 200hp more than this car and my S2000 has nearly double. I have found that using the manumatic feature of the transmission really helps to make the most use of the power because the transmission is really slow to react.
The car handles very well for being an econobox.
Noisy, I am not sure if there is any sound deadning on the car.
The fuel economy seems good despite how I have been driving it (been pushing it to make sure everything is OK)

Thanks for the help thus far!

 

[paper1122]

Yet another update for those who are reading:
Replaced both belts with new Gates belts. Seems to have taken care of the noise, but a cold, damp morning start will tell.
The K&N is in.
I finished the hatch area carpet, it turned out really well. I suppose I should take some pictures.
I painted the window trim around the back side windows. It took a while to mask it off but it turned out really well. I used the Duplicolor trim paint. The old paint was very faded.
I haven't received the bulbs yet so that hasn't gotten done.
If I paint the rims it won't be until after Christmas.

Tomorrow I am going to pull the bumpers off the wife's old car so they can be repainted before I put it up for sale.

 

[paper1122]

Pulled the bumpers off the old car today.
I also programmed the new key fob that I got off of ebay. I am very glad to have two sets of keys and fobs for the car.
The wife is very pleased with the work I did on the rear hatch carpet.
We are very much considering taking the P5 home for Christmas this year instead of my truck. Assuming I can get the alignment done this week I think we will. There should be plenty enough room. For those thinking that I am crazy for saying that it "should" be enough room. We pick up my aunt from the airport on the way to my parents house so we have to have enough room for: our luggage, Christmas presents for 15+ people, my aunt, and her luggage.