OK last few days a lot got shipped...

received--Radio harness, a/c compressor, Radio side trim pieces, MOTOR...

I went to Mazda last week to order some gaskets and price out a rotor housing and rotor. I asked if Mazda did a reman program with their rotory motors. My Mazda parts guy said they did but it’s been discontinued years ago. But for fun let me run the reman number to our warehouses. None where in the warehouses, so he ran the number to all dealers in the usa.

Some dealership in PA showed to have one in stock. So I called over there and asked if he has one. He did. I purchased it at cost for $2,075.00

I asked a little bit about it as i was a bit wary about a motor that’s been stuck at a dealership for so long. Anyone who works in the parts business at dealerships know if a custom ordered part comes in that someone ordered and they never pick it up the dealership is stuck with it Because Mazda won’t take it back.

Well some guy ordered it 9 years ago and traded in the car. The dealership never repaired the car and was stuck with the motor.

When the motor came in myself and a senior Mazda tech that now works with me went over the motor to check for rust or anything that would make us return it. No problems found. Everything was brand new.

The last Mazda reman Turbo II for the S4






Came with a new flywheel, oil pan, front cover, pully, water pump, thermostat and housing, and radiator cap.

 

That is ******* sweet!

 

one thing that is throwing me off is the radiator cap neck. there is no nipple for the overflow bottle. Mazda has a old service bulliten for the 86 and 87 motors for the coolant level sensor buzzing. the fix was to install a new filler neck and route the overflow line to the sensor on top of the radiator.

so i need to get that kit OR since my nipple broke off get another cap neck.

 

Correct me if I'm wrong, but there is no line coming from thermostat filler neck on S4s...at least mine doesn't have one. The only overflow line comes off the radiator, the neck on the engine just has a sealing cap, no pressure relief.

 

My S4 N/A came without a line from the filler neck. What J5sense is saying; "Mazda has a old service bulliten for the 86 and 87 motors for the coolant level sensor buzzing. the fix was to install a new filler neck and route the overflow line to the sensor on top of the radiator."

Almost like a "recall"?

 

Well, that certainly solves your engine problem.

Were they able to tell you what parts are used in a Mazda reman? As in what might be new, what is reused, etc. I used to remember, but am drawing a blank now.

 

9 years ago it would ve been new housings and a real good build, im lucky as well the car i bought had a brand new mazda reman motor in it with 3000 kilometres, the motor was installed 10 years ago before it went into storage, so now the motor has 6000 kms and pulling strong lol

 

good to read a build thread, it's getting me itching to start mine back up. if only i had more time in a day.. week.. month..

 

9 year old rebuild probably needs new springs. I've been told that the springs will go flat without the heat cycling of the engine running.

 

good thing theres a reman warantee?

 

nope I've got a reman in my car that sat for 10 years infact my whole car sat for 10 years, and my motor had 1500 miles before it sat for that many years

 

Wtf! i was typing a huge post and the screen refreshes and i loose all of it. arhhhh

 

I don’t see how the springs can go flat from sitting. On a normal car some valve springs stay compressed when sitting. I’ve never heard of any problems.

Anyhow, Last couple of days I have been pricing out and ordering stuff for the motor. I was at Mazda and got some maintance stuff as well and odds and ends needed to put the motor back in the car.
I ordered the gasket kit from Adkins Rotary tonight for when I put the motor back in the car a week from Friday hopefully.

I sent out my very dirty fuel injectors to Witch Hunters and they did a awesome Job. They clean them up making them look brand new. They then clean them and give you and before and after printout. You get your injectors back with all new seals. Very fast turnaround time and you can pay with PayPal too. Great communication too.



To fill the hole in my car where the radio once was (all i had was cut wires) I found a almost mint S5 factory radio. After all day of figuring out the wiring I powered her up and everything works! The S5 radio in S4 body was a bitch to wire up but it can be done. It lights up, Display works, sounds decent, and the cd player works. Only issue I have is the door speaker’s don’t work. I need to run wires to the door amp and ire that in. That’s a later project as I am happy with having something instead of nothing. I am a fan of the stock look but its almost impossible to find a working 1987 turbo II radio.



So Next Friday I will start installing and hopefully have her running that Sunday!

 

I am still waiting on the gaskets to put the motor back together/// so i decided to look at why my sunroof wont open.

When you press the button the passengers side popps up and then stops.

So I decided to tinker and ended up with the headliner down then pulling the whole damn thing out.

Long story short, i found the right side cable seized up in the guide tube.



this picture below is what the other side looks like after i cleaned it and the sunrood tracks out and lubed them up.





So i think im gonna soak it in pb blaster tonight then if it wont break loose ill hit it with some map gas (light torch)

Oh and honda filters work on the rx-7 too

 

Im loving that red interior.

 

its "porno red" classic 80's colors... my last project car (1985 300zx) has a blue interror :-)

 

looks nice!

wish i could find a motor like that!

 

ok, so the sunroof cable was broken :-( the other half is still soaking, but ill probibly need the tube too...

Bummer. I was hoping for a easy fix.

Today I installed a new power antinna mast, and painted the exhaust heat shields with that 2000 deg paint. hopefully it all wont burn off right away.

I also painted the lower manifold and some other things. Ill repaint the upper sometime this week. The pain in the *** was cleaning and prepping.

 

Ok so the sunroof cables are $40 bucks each and the regulator tube system is $180

The master mazda tech said you should replace the cables as a set because they strech and will cause the roof to open wierd.

I was not trying to open a can of worms with this sunroof so i am going the cheap side and just ordering the broken cable and trying to soak the regulator in pb blast to try and save it. Im gonna bring it to the shop tomorrow and might hit it with the torch

I think it will turn out ok. The other cable looks almost brand new and it only has 60k miles on it. Plus there is some adjustment for a streched cable.

the sunroof assembly is really quite simple when compared to newer honda sunroofs.

I finished painting the black paint items today. I ran out of aluminum paint so im gonna have to pick up more tomorrow am to finish a bracket and the upper intake manifold.

My complete gasket kit will be here wednesday so i can start rebuilding the upper and lower intake manifolds and the turbo...

its going to be a eventfull week. sunroof going back in thursday, motor going in friday sat sun. hopefully a running car sunday. tires, fluids, and brakes the following week.

 

Rats nest with new silicone hoses and cleaned connectors



oil filler neck and random bracket


pulleys... gonna paint the center bolts aluminum

 

Nice project. Looking forward to seeing the progress. I think the radio you need/want to be original is on Ebay now......check out this item number 130544666766. I am not at all associated with this. Just a heads up.

 

Wow, nice condition!

 

gonna be a crazy day tomorrow.

Here is what i did tonight.

put new gaskets and orings on the intake manifolds and turbo. cleaned them up all pretty too.

installed the lower intake and turbo. got all the turbo lines hooked up.





thank god i ordered a new fuel dampner. The screw was out rattling around.

 

I wish I could even afford a turbo car, great build though.

 

you seem to have amazing luck (with the car and the engine).

anyway, amazing build so far. i love it. i love your approach.

i'm one of the ones that would rather see you leave it fairly stock-ish, aesthetically speaking (tail-lights and such). my personal feeling is when you start putting S5 body parts on an S4, it should be an all-or-nothing affair. when they mix, it tends to make the car look a bit odd - not bad, necessarily, but definitely odd.

on a somewhat related note, i'll try to keep you in mind as a resource for sunroof work because i have sneaking suspicion that whenever my Gen II is finally up and running, mine will probably be screwed, too. so i may shoot a few questions your way.