Ok, I gotcha now. The car is an '86 GXL manual transmission so no fan. That makes sense that it doesn't connect to anything now. Thanks for helping me out.

Now I just need to figure out if anything plugs into the yellow connector under the dash.

 

The plug under the dash is probably feeling left out and all since you provided a pic of a plug you don't need. Perhaps a pic of this yellow connector would help. And is this yellow connector by the steering wheel?

 

Haha. The plug is behind the fan under the dash on the passenger side. It is connected to a plastic tab that keeps the plug facing upwards.

 

nice work man. i think i saw this on jdmcity.com a while back.
i live on the east side of dm man 8)
i know its like thread jaking but do u know how to rebuild rotary motors?
i have 2 rx7 with bad motors and one just chilling there that needs rebuilt.
i would love to learn how to rebuild them 8)
u should pm me if u can 8) n we can talk

 

Pretty sad when I necro my own build thread. Oh well. After way too long, I made some progress yesterday. My good friend Matt drove two hours to help me work on the car for a bit, so we buckled down and got some work done.

The Good:
I had been procrastinating putting on the upper intake manifold because of the wiring harness and vacuum line routing. It seems like a lot of people do the S5 engine into a S4 swap OR they remove the rat's nest. Very few people do it at the same time, so trying to figure out where everything goes while having to deal with S4/S5 issues. However, I had some diagrams printed out and was able to get a majority of the vacuum lines hooked up. I still need to cap a bunch of vacuum ports, but that should be fairly straight forward.

While I was working on the UIM, Matt was busy pulling the sheathing off from around the engine wiring harness. Because of how it was routed, a few of my plugs (mainly the primary injector and BAC plugs) couldn't reach their intended destinations. Instead of fighting to find a few extra inches to pull the wiring harness around, we decided to strip the sheathing off and reroute the lines. This would also make it easier to tuck away the solenoid plugs I won't be using. He was able to locate all the plug locations so now, I simply have to rewrap the wires to protect them and get them secured in the engine bay and I'll be able to finish hooking everything up.

About the only bad thing in the engine bay is the injectors seemed to be seated very loosely. I think I'm going to end up just getting new injector rings so they fit tighter.

The engine at the end of the afternoon:




The Bad:
I was dreading opening up the fuel tank in the car. I bought it with a blown engine 5 years ago and have never driven the car. It sat for 2 years before I bought it so I figured there would be a nice sludge waiting for me to pump out before I got around to filling it with new fuel and starting it. Well, I got the access plate removed and started removing the screws for the pump. I was greeted by a nice stale gas smell as I cracked the seal. Upon pulling the fuel pump, this is what I saw:




The Ugly:
Of course, I looked into the tank and found no sludge or stale fuel to pump out...only rust flakes.




My next steps in getting the car running are:
1. Figure out if the injectors issue and possibly get new o-rings
2. Remove the old fuel tank and get a new one
3. Probably get a new fuel pump or fuel pump assembly
4. Wrap and secure engine wiring harness

As long as I can stay motivated, it shouldn't be too much longer until I get to try starting the car.

 

That is by far the worse FC tank i have ever seen!

Im not sure if you know this but make sure you get the same series gas tank. S4 tanks are slightly smaller. I once put a S4 tank on a S5 and the straps wouldnt get tight because the tank was smaller. Just a heads up.

 

Thanks for the heads-up. I'll remember to stay away from S5's when I'm looking for a new tank.

 

I was able to find a good condion S4 tank and pump at the junkyard I went to. I was hoping to find a S5 tank for the larger capacity and deal with the fuel pump wiring and larger straps. However, at the yard I went to, they only had two S4's.



While I was there, I also picked up a few other goodies that I needed. I got a rearview mirror, P/S idler pulley, the plastic piece that the radiator cap screws onto, and a radio with the EQ, tape deck, etc. Those goodies, along with the fuel tank and pump, only set me back $50. I was pretty happy with that.

Sadly, about 2 months ago, I messed up the engine in my daily driver while autocrossing (oil starved the motor during a high-speed, sustained sweeper) and I have been needing to get the engine tore apart to install new bearings. As I was working on the 7 this weekend, I couldn't get the fuel pump to pump fuel and I think there is an issue with the starter (wouldn't do anything when I hit the key), so I made an executive decision to swap out the vehicles in the WRX-7 garage. The focus has switched from the Mazda to working on the Subaru. Hopefully, I can get the Subaru rebuilt quickly and get back to working on the Mazda.

Until then, this is how things set:

 

Any updates so far?

Id like to see your GXL roll soon if its not already done.

Im finally getting my resources in order to start mine next month when it cools down enough. By then Ill be locked away in my garage 24/7..