psyaddict

Fuel pressure regulator connected to fuel lines

I hate Estonian post but anyway i have my gauges in place.. sort of


Here's the ECU box

And this is how it should look like:

We're gonna start making the wiring and ecu after the summer solstice, this week i should get my clutch cylinders and a bov flange, fingers crossed.. they're already in customs..
So i am enjoying the summer warmth and working til i get money for the missing parts, starting with secondary injectors and oils.

psyaddict

a little update, all this is a few weeks ago.
New clutch hydraulics ~60$ from ebay

bleeded and works nice now!

So a while back i bought a mx-5 injector overhaul kit with all the o rings and stuff to get only the rubber grommets to seat the injectors to the engine/intake, i didn't know it's a mazda thing that they have these on the injectors and sold my old without taking them off -_- from the price of these they should be made out of gold. And i still had to buy extra viton o rings because the miata o rings dont fit.
Finally i got my siemens primaries in place and they are longer than denso's...i already knew that. So theres a few centimeters of room between the fuel rail bracket and the engine, but i have a pile of s4 n/a fuel rails in the shelf. Then i just cut the n/a one, place it in there and its sits nicely.


Painted the cooler with a light coat of black semi gloss paint for stealth. I dont want any trouble with the law enforcers.
BUT even before that theres a problem with getting the technical inspection done, police investigation in every place where it could have been done to a fast car, so i'm not sure if i can get it inspected and without technical inspection i cant get it registered again (the system does it automatically online)

And like the last few summers my 626 wagon needs "some" work, horrible noise from the rear suspension + big bodywork and it seems i need a new timing belt kit also.

psyaddict

iv'e been really busy lately. almost no time for the car itself - i'm moving to a new garage, what a headache.. i had enough of the crazy old lady who freaks out on everything, no smoking, no talking and if someone of my friends comes to my garage with a car then we get some really nasty yelling towards us.. the style is like "wtf are you doing here with the car, don't you have any legs you fking douchebag?? what the hell are you smoking there you ****?? can't i ever get some silence here?" not the best garage owner.. also the ceiling is leaky, feels like an amazon forest, there was some heavy rain in last days, all my stuff is in cardboard boxes and now they sit in pools of water, i took the shelves apart already.

Last things i did:
cleaned the turbo pipes inside
below is the prototype, almost lost my fingers

put the lip under the bumper, first time i see my own car with it. just sat there and watched it for a while with the lip attached .

connected the pipes and some electric connectors nothing big.
next update will probably be when i'm done with moving.

psyaddict

I have moved!
looks like lot of fun in the video
In the last garage i felt like a cockroach or a mouse because of the crazy evil owner lady, really liberating feeling in the new one..
Quite big changes in my life, i also got a new job @ Toyota dealership as a mechanic and also i got a new phone, so i can take better pics what are not fish eyed.
Bought five-o injectors, should arrive in 2 weeks, hopefully making the wiring this weekend and ecu soon... welded the bov flange and to make my free time (while waiting the injectors) useful i started bodywork on my 626 wagon.

psyaddict

psyaddict

so the repair of the 626 wagon went overhead, typical bodywork, just wanted to repair a little and it became 2 months of work.
Little pics if anybody is interested:



And then my stepfather calls, and tells that he's gonna get a new car (not a mazda this time, because a škoda can be registered as a van) and i can buy the old one because we have the same

it was so badly rusted that it fell off and broke the car lifter while i was removing the engine, luckily no one was hurt or dead and no parts damaged that i needed. especially the jdm rear hatch






and i'm still not finished with this car, have to do it in summer.
Putting parts to my daily from a facelift model is a NIGHTMARE, nothing matches.
Many lessons learned, do not mess with the car you need for transportation, whole life stops.

psyaddict

Now i have the secondary injectors, they have been in my ebay shopping cart forever and tho i forgot to tell them that i need these for mazda. So here are the fiveo injectors for an american car!

The mazda fuel rail wasn't gonna work out, so i bought some fuel rail material and made my own.
I'm also back on my old job, nothing better to make your fuel rails and get payed for it.

ground down a drill bit, but it wont work on aluminium kind of melts it back together.

psyaddict

making an exhaust for starting the engine, just a pipe no mufflers or anything


The wizard soldering my ms2

taking shape

psyaddict

temporary pipe

then i put the lim on

new connectors, cas for example

and now some pics of wires:


A little problem with the tps wiring colors on the oem harness, they do not match with any manuals, maybe the color is faded or smthng.
So now the only thing to do is to wait some AN fittings to arrive (couldn't afford to buy them locally)
and weld some holes on my daily.. the old man at the yearly technical inspection told that he has to write a novel about all the things wrong with it

psyaddict

Progress has been really slow, I am still waiting for some of the AN6 connections, especially the Y piece, I ordered it in NOVEMBER
Just ordered another one from a nearby country. hope to get it this week so i can finally check my fuel system. I guess I have a few days to put new wires on the pump while the stuff comes.
Felt bad that i haven't been on the garage lately so i decided to do something.
I'm also putting some smaller pic's in here, the load time gets annoying..
Wiring

Covered the drivers side washer tank fill hole with the piece left over from the boost gauge hole

Attached the coils, couldn't find the bracket so i made a new one

found a new place to sit for the leading coil.



Had to re-route the coolant, since it doesn't run in the intake anymore, but this looks stupid running over the manifold, no such problem with the fd intake.

Gauge pod wiring



Glove box in it's place, gauge wires will end up there..

psyaddict

gauge lights are working

only thing that the oil pressure gauge is a different series (looks almost the same) but the lighting is not so bright, which is okay i guess but i may have to add a dimmer for the others if they end up too bright.
Re-wiring the fuel pump also, a bit worried about the old wires and low voltage

BUT if i'm using the old connectors/plugs then is it any help that i put new wires there?
Or should i just drill new holes to the pump assembly and push the wires through and seal them with gasoline proof sealant?

psyaddict

fuel hoses done, i dont like this solution, but it will be fine for starting the engine..

psyaddict

got some new belts

Got the sunroof aligned, ofcourse some things broke while doing it..


glued those pieces, should hold until next time

sits nice now

psyaddict

wiring is almost done, we have power on the coils and everywhere we need it. Attached some more wires what were loose, checked every important bolt and nut, tightened if needed.
UIM holes welded shut:

bought some coolant, 2 stroke boat motor oil (drove through many shops nobody knew what the hell is a tc-w3 oil, even bought some redline 2stroke but it was for air cooled engines and I returned it), E98 fuel, cheap 15w40 mineral engine oil (it was the only option- disadvantages of living in a small country)
Gearbox also has cheap oil in for now, just for checking if everything works.
Premixing party:

fuel pump works, i thought everything was tight but found out that there was many leaks, all fixed now. So we thought we'll try to turn the engine, to pump the oil up and so on.. And it didn't turn over, i mean the starter did not work.. so I removed it and found out that the starter itself works but the solenoid thingy that pulls the pinion won't engage.
Pulled it apart, cleaned and greased it- still nothing, doesn't have the power to pull it


I think i might have a starter somewhere in the parts pile, gonna dig in
For now it sits like this, til i get the starter problem fixed:

psyaddict

found some starters

all different but still mitsubishi and the part i need is identical on all of them
assembled and works fine, put it back on the car, maybe start the engine this weekend, if i get some propane. I basically hold the doors open when i was in the garage because it was warmer outside

psyaddict

Still no heating in the garage, it's really damp and cold there and no one besides me is willing to be there for a longer period of time. Probably getting that problem solved in a few days.
The good thing is that the starter works good, oil pump is pumping the oil and i just have to look up a few things. Hoping to get it running inside this week.

_Tones_

Been following your build intently so far, loving it! SO cool to see you persist in a country where no doubt sourcing parts etc is difficult

One thing though for some reason in your posts some pictures post normally, and some post as little thumbnails, kinda kills the flow of the thread

psyaddict

Yeah, i like big pics much better myself, but the load times can be rather long, depends on internet speed and/or computer.
But I'll keep that in mind and post big pictures in the future

psyaddict

Now i have heat, but i need the ecu guy and he's busy, if luck turns to my side, it will happen on this weekend, tomorrow is a free day for everyone, our country's 99th birthday, and also my name day so people are doing their own things.
I can't wait to start the thing, its all ready damn it, spring is coming too fast and i'm really anxious, this year I may have a chance to drive with all the people who are bringing their projects out of the garage.

psyaddict

meanwhile i finished (almost) the gauge wiring with the help of my woman.
from this:

to this:

took us til 3AM, i was quite confused at start, didn't remember much from the last time i dealt with these wires, but it all came together nicely, hooked up to the senders and everything, forgot i don't have a coolant temp sender but, i think we can use the oem sender to the ecu for accurate temp. reading.
Keeping my fingers crossed for the startup today.

psyaddict

We had some problems yesterday.. the ecu did not get a proper signal from the cas, not the cas problem i think, if resistance is measured directly from it then it changes in even impulses, also i think the oil pressure sender is not grounded good enough (when ignition is on it goes over maximum) a minor oil leak (easily fixed) and some other stuff i can fix later.
Maybe we're lucky today

psyaddict

why the fk is it not working?


Luckily he had enough parts with him to put together another megasquirt, changed the processor or whatever it was (i was diagnosing faulty gauge readings at the same time so i don't know) put new software on it and it showed rpm!
The problem still remains a mistery why the first one did not work, but my friend said that even if it wont work on a rx7, it can still be used on a bmw so it's a win

Video:

I cant believe how easy it was to fill the cooling system without the coolant going through the intake manifold wohooo! Last time i did this it took me 3 days
The turbo didn't turn around at first, it hadn't been used for many many years, but at some point i noticed it twitched a little and with the help of my hand it started running, I even felt some airflow from the loose pipe after the intercooler.
Now I'm motivated to work on, gonna rest today though, hard to stay awake @ work.
Lots of loose ends to finish.

psyaddict

small update
the problem was that the ecu did not read the second triggerwheel, so he made many changes to the schematics, finally restored the first one, put a new processor on new firmware update and it started working. Later he watched the log and discovered that the first time the battery voltage was probably too low while he was loading the firmware to the ecu and because of that it didn't load on properly.

psyaddict

Spring is coming fast, days are getting longer and longer, it's still cold but the sun can keep your back warm nicely, has been a long time since i have felt so good in this time of the year.


I took off the intake manifold to make some holes for vacuum hoses and this is what i saw:

large grain sand in there, I have NO idea where it came from, can't be airborne dust, it's too big for it. I made sure to put everything together clean, It seems i wasn't careful enough. Or maybe it was already there the whole time and I didn't watch it with a flashlight before. Hope it didn't get into the engine, the lower butterflies were closed I think and the carb cleaner had made the inside of the manifold sticky so maybe most of it stayed on it's place.

Anyways, I then cut a thread on the intake thingy to mount the air temp. sender

To the manifold for ecu, boost gauge, bov and fpr

For the wastegate


Found this @ work by an accident

I was not aware these pieces existed at all, but it was just what i needed for the boost gauge. Plastic hose --> rubber hose


Looks something like this( the hoses are a little longer than they should, just in case, i can always cut them shorter)


But I may have a problem with the vacuum from the UIM, It's divided- I'm not sure if i can get correct vacuum value to the gauge and valves if they're connected to the lower part of the UIM, what I mean by that is the upper primary butterfly (what lets air to the middle iron) Opens before the secondarys open in the throttle body and i have most of the hoses connected to there.. Anyone has any idea how it's gonna work?
Could i drill a small hole between the chambers? The plastic spacer thing (between uim and tb) does the same job with the small vacuum holes and channels in it, right?

ecu got vacuum from the upper chamber, it also can get false readings i think, when under boost?

Then i found some loose wire connections, big ones, under the dashboard on drivers side, now the idiot lights work (hopefully it will start charging battery, last time it didn't) Then one of the headlights popped up, but they wont go down the sunroof and ventilation fan also do not work.. yet.
Finished the day with a sticker

psyaddict

So i have been messing with the cut wiring to get everything to work again. Oh man how much time it all takes, finally i managed to find those two connectors deep under the dash, on the passenger side and that made everything clear.. almost. The next day I found a piece of wiring what goes between those two and some other connectors and then i finally got it.

I haven't tried everything yet, but now i should have working turn signals,windscreen wash pump, cruise control, sunroof(still slow), headlights (new H4 connector on drivers side, but unfortunately 1 wire for motor broke) just about everything works, even the wipers on slow speed- that means I have to replace the relay, theres instructions on fc3spro, and i think i can get the relay from local electronics shop.

The one I need is named G6C-2114P-US-DC12 G6C-2114P-US-DC12 Omron Electronics Inc-EMC Div | Relays | DigiKey

But they sell G6C-2114P-US-12V https://www.elfadistrelec.ee/et/pcb-...=10&simi=85.23

To me it seems its the same part, at least the features that are written there are the same.

I haven't been able to be in there for 5 days now, but i really miss it because it's so much fun!
The board is getting too small for the to do list, i'm constantly adding more

The wideband gauge is almost installed,
Still need to do:
+headlight mod
+redo the fuel lines
+oil leaks from turbo
+gearbox wiring
+...........

+ stuff i need to buy