Any one in the NE area know how to do a S5 VDI manifold swap?
 

Hey guys, I live around Boston MA. Is there anyone around that's done the VDI swap? I was wondering if anyone could give a hand with the swap or recommend a shop that could do it. Though I'm a college (read as: don't have much cash lol), I'd of course be happy to give some compensation (Some beers or a little bit of cash). Anyone able to help a fellow RX-7 owner out? Any help is greatly appreciated :)

Its very easy with some time and a little modification.

You will have to find out how to operate the VDI though. I operate mine with a lumbar air pump and rpm switch that works very well.

I don't know who else can do it. If I had the car at my place I have everything to do it plus the manifold and spare parts. I live in NH. About 50 min from the border.

Do you have an tools? Grinder? If so then you could do the swap your self.

Here is some more information on the swap.
http://howto.globalvicinity.com/gv_w...i=63&co=1&vi=1

Thank you for your reply, I bought the LIM & UIM already off ebay. Parts I think I still need is the VDI actuator/solenoid, one of the S5 fuel rails, some gaskets and an RPM switch.

I have the necessary hand tools, and a good drill + bits, but don't have grinder, maybe I could get one for my drill... What tools do think I might need? I figure the usual sockets, ratchets, torque wrench, right? I have a haynes manual as well...

I'm guessing it would be a little over 2 hours to get up there.

The things that worry me the most are the vacuum lines and the VDI activation (want to use the stock air pump on it), I'm going to try to keep most of my emissions stuff because of the MA sniffer test. Most of the Emissions junk seems to be on the LIM anyways so I shouldn't worry too much about that.

Do you have any advice when approaching the project? If I can't get all the necessary tools/materials I might be taking a trip up to NH, :P If you don't mind that is.

I have the VDI Actuator and both fuel rails. I also, have a summit rpm switch that im not using. Im not using it for a reason though, those switches ramp up the voltage when getting near the activation rpm and if you are using a cheap relay or a radioshack relay, it will make it stick in the OFF position. I would reccomend the MSD switches.

You can't use the EGR for the S4 engine since the manifold will come in contact with it and the manifold will not seat at all. So you would have to block the S4 EGR off and use the S5 EGR which is on the UIM and you would also have to use the S4 LIM if you want to keep emmisions since the emmisions ports on the S4 LIM are below the front and rear port runners. On the S5 LIM there is only ONE emmisions port and that is in the center of the manifold.

So in that link I gave you above, Steve shows you how to grind and drill a hole for the S4 LIM stud to seat into since the stud pattern is slightly different. This takes some time. I have a dremel which works good for this though, although my air grinder is good for it as well.

- Screw Drivers, Philups and Flat Head
- 10mm, 12mm and 14mm sockets and wrenches.
- Allan keys for the block off plate for the EGR. They usually come with allan screws.
- Good pair of pliers
- Grinder, either air or electric.
- Don't need a Torque Wrench and the haynes manual may not help to much.

The best writeup to read is the link I provided.

Maybe a few other tools im not thinking off but I think that about covers it.

For vacuum line routing and emmisions operation after the swap im going to look for the link for that information. A guy did the swap while keeping emmisions and he did a writeup on it, and infact, its the writeup I followed and researched when I did mine a few years ago. I will see what I can dig up. I don't have emmisions on my engine so I did not have to think about it.

Research it first. I can tell you all day long but I would read the link in my first post and also when I find the other link I woul read over that.

You will also need new new intake gaskets

S4 LIM to UIM Gasket. Fits with S5 UIM.
S5 UIM to DC if they have been seporated.
Hylomar is great stuff to use when fitting gaskets together since the stuff never dries, it seals and protects the gaskets and also makes seporating the manifolds down the road easier without ruining the gaskets and buying new ones.

If you don't have everything to do the job your more then welcome to come pay a visit. The only days you ould be able to come are Monday, Tuesday, Wednesday. Since those are my days off. Hopefully You won't have to work those days :)

ok I found the link
http://homepage.mac.com/carldavis/intake.html

But he tries to keep emmisions, and he blocks off the split air port which is the emmsions ports I was talking about. He also uses the S5 LIM that you can't use when keeping emmisions.

SO. Back to square one. Let me do a little research on how the EGR and such works on the S5 and I will let you know.

Right now, You will be able to use the S4 ACV, S5 BACV. Im going to see if we can use the S5 EGR.

Ok, it appears the S5 didn't use a EGR valve but im looking into that.

Ok, No EGR on S5. Confirmed. Hailers has passed emmsions countless times without EGR and since S5 doesn't use EGR, You shouldn't need it.

So S4 LIM with S4 ACV for emmisions.

I don't know what PSI the air pump puts out at 3800 rpm but you could easily tap into the hose from the air pump and put a pressure/vacuum gauge on it to see. You could then run a line from that nipple to a 3 way solenoid valve hooked up to a RPM switch.

Should work just fine.

Vacuum hose routing you can get from the FSM.

Awesome! Thank you for all your help and knowledge. I've going to keep studying up the both DYIs. I better start collecting the fuel rail, switch and solenoids I need. I'd like to do a dyno run before installing it to get a base run :)

Could we maybe meet up the first or second week of August if I haven't got it squared away by then? I'll do an after dyno as well.

Sure. As long as it lands on Monday through Wednesday. It would be an all day project. :)

Cool! My job is really flexible in August, so I can take any given day off as long as I do my hours for the week :). Since you seem to have everything I haven't boughten already, could I possibly buy the stuff I'm missing, from you, then?

Yup you could.

I do have the secondary fuel rail and I have a primary rail but its a little banged up and I would be embarresed to put it on someone elses engine so I would look for a S5 Primary fuel rail if you don't have one already.

If you would like, you can use the summit switch I have untill you can get a MSD switch that I reccomend. I also have plenty of 3 way electronic solenoids to choose from to open the VDI.

I would say $50 for the Secondary Fuel Rail, Summit Rpm Switch, Electric Solenoid and VDI Actuator.

Sounds like deal, thanks! :) I would also like to compensate you with some cash for the trouble.

^ Sounds good to me as well :)

If you get another RPM switch, you could run the AUX ports off the stock air pump like the VDI. This would allow you to open up the exhaust without worring about the Aux port actuation.

Would the summit rpm switch do?

The summit switch will do for now for the VDI. IF you want the Aux ports to run off the air pump you would have to get another rpm switch. I woudl go with MSD.

btw, I think I forgot to mention that you need to buy a EGR Block off plate.

You can buy it here
http://www.2751engineering.com/fc3s_..._plates_89.htm

Yup, thats the switch.

I was looking at my spare 89-91 ACV and I noticed it has the port for the VDI and AUX so we can use that instead of the S4 ACV since we would have had to make an adaptor to fit in the hose to allow a vac line to branch off the air pump hose. This way it will be nice and clean.

The plungers in the ACV seem to move freely so the ACV should work. I will have to test it properly to make sure it works though.

Since we will use the S5 ACV, if its good, you should order a new ACV gasket from mazdatrix. This way we can remove the old gasket to check the ACV check valve which is sometimes gunked up and not allowing it to funtion properly.

Hey BTW could you please PM your email as well, or perhaps a number to reach you at when August roles around. :)

BUMP! Anyone else in the area? (Boston)

Rotorman what days are you available nowadays? I can't wait to throw on the VDI and the header I have:ylsuper:

Does anyone know what the ACV gasket is (the acronym)? I'm having some trouble finding it. Thanks!


edit: never mind found it!

You have 2 RPM switches now correct?
Were you able to get your hands on a Primary Fuel Rail?

aaa.....nope damn forgot about the primary, I though we could get away with the stock piece. I'll order the 2nd RPM switch ASAP. Got to get the middle gasket too (between the uim and lim for the s4 right?)

BTW what's your opinion on pineapple intake sleeves?

Ya you can't use the S4 primary rail, it will hit the underside of the s5 UIM and won't alow you to install it.

You need a S4 UIM to LIM gasket.

I heard nothing but good things about the pineapple sleeves. You MUST install them correctly. I believe I heard thread locker or something of the sort to hold them in place.

Ok buying the MSD RPM switch tomorrow :) BTW what do I about the pill/chip? Do I need to buy a specific chip? They look like resisters to me? Thanks!

The only thing I'm worried about getting is the primary fuel rail for the S5! I'm not sure where to get one, or how much they cost.

Stuff I've bought:

1)manifold (all 3 pieces, they have not been separated)
2)RPM switch
3)ACV gasket
4) Middle manifold gasket (will buy now)

need to buy:
1)Primary fuel rail.
2) MSD chip/pill?

buying from you:
1)Secondary Fuel Rail
2)Summit Rpm Switch
3)Electric Solenoid
4) VDI Actuator.

Wonder if this a good time to order & install pineapple sleeves? Then again, your already helping me a lot and I don't want to add unneeded time for the project, perhaps that will be a good project for another day :). In any event VDI sounds awesome I can't wait to see the difference.

Ya thats the primary rail you needed :)

Ya grometts and o-rings would be good. There is a store near me, about 25min away that has all sorts of grometts and o-rings, bolts, nuts and stuff so if we need anything, we can go there.

If you can pick up o-rings and gromets though, that would be a good idea. I may even have some. A small o-ring kit from the autostore works wonders :)

Mazdatrix.com sells the o-rings and gromets too.

If you can't get everything in time we can always push this off untill you do.

the list looks good. Im going to go put everything in a pile right now. I hope I havn't misplaced anything.

Actually, Pineapple sleeves would be a good idea to put in while we have everything apart. Should be only an extra few minutes to install.

Remember, this is not going to be a 2-3 hour job.. The earlier you can come, the better! Im up at 7am on my days off anyways. Plan for about 5-7+ hours.

I charge $150 /hour :naughty: :rlaugh:

Sweet so the only thing missing would be the o-rings and gromets? Great!

And optionally the Pineapple sleeves, I'll see what I can do about those, and the needed S4 LIM gasket that would be needed. If not that's no big :)

Alternatively my next day off from the university would be October 8 (Monday) Columbus Day. IF you free AND it's NOT any trouble that's another good tentative day. Hmmm...which might be considered for the sake of the pineapple sleeves...lol
I'll be knocking on your door at 5 am then:D The earlier the better for me as well that way there's no one on the highways:naughty:

As for your rate I hope you mean pesos... or even better in Yen, cause I'm a college student....

Though some compensation & beer are in order;) LOL

Ya I was just joking :)

Its been a while since I have had anything to drink, after one beer, I would probubly either A) Stumble around B) Screw something up your engine, I acutally drove around with a bad o-ring once on the secondary rail pissing on the exhaust manifold because I was drinking while working on my car......enough said. C)Pass Out.

You guys can have the beers though :) As long as you can drive home safe. I suppose whatever you can afford, I know how it feels not having much money, I feel like that all the time with my bills.

No worries bro, I know you were joking lol:D Nah, no drinking for us lol, I actually want to learn something. and want to be 100% focused. As a rule I never drink and drive not even one beer, ever. But I thought you'd get a laugh out of the offer:D

We'll buy you some lunch though, a nice foot long sub, maybe a pizza or something. Whatever you want.:ylsuper: And will bring some coffee/soda as well, maybe some dunkin donuts bagels/muffins too. Nothing like a good cup of coffee in the morning to get you going. And even us poor students have a small stash of cash hidden;)

Hopefully I'll pick up a couple of pointers from one of the local rotary experts.

I just remembered what to use for the pineapple sleeves, LocTight.

Pizza is always good! If you buy enough of it so I have lunch for the week at work that'd be great! :)

Mountain Dew usually gets me going in the morning :) It what my buddy and I usually drink when we called our shop (my barn) Midnight Auto as our inside joke. We worked second shift at the same job at the time so when we got out, we went to my place to work on either his car, my car, my girl's cars, or someone elses car. Stayed up to about 3-4am, then went to bed.

Do you have a SAFC? I forget if you said you did or not. If you do, or plan on getting one, we could throw on a S5 throttle body so you could use the full range TPS for the safc :)

There are plenty of local rotary experts around, even I would like to meet the others. You will be wrenching while I eat pizza so you will learn something :)

No steeling my tools, I'll have to kill you!

While typing this I just heard one of the many v8 hot rods fly by, so while your here, because we are in the sticks, you will probubly see a blue car fly by that I can only guess has something done to its big block. I don't know if its the rx7 or what but almost any car that drive by with exhaust or modified engine, always either floors it (automatic) or throws it down 1 or 2 gears right at my house.

Damn rednecks. I may not beat them in a straight but I will probubly beat them for being able to hold my engine at 8000rpm without worrying im going to shot a rod through the side of my block and launch a piston into the head hahaha :)

Actually I can't seem to find my spare S5 TB. :uhh:

Lol, no worries, no I don't have SAFC, yet. I can't decide whether to go with safc or Rtek7. SAFC is cheaper and gives nearly the same results though :) I got the Manifold and ACV gaskets as well as the fuel rail today. Just waiting on the RPM switch, should be here by Friday.

Actually the Rtek is way more advanced then the SAFC. You can adjust ignition timing and fuel curve unlike the SAFC which is only fuel and only modifies the AFM signal into the ECU where as the Rtek adjusts the fuel without faking its self out. There are a few other cool features by the rtek. I was going to go that route but I want to get rid of my AFM so im going to go with Megasquirt.

Sweet deal, I hear some of the guys around here say there is like 10hp to gained through tuning the engine. BTW I forgot to mention I have the Blocking plate for the EGR as well I got it yesterday.

Aight.

Ya tuning the ignition timing and fuel will a lot of times gain you over 10hp. I advanced my timing and add fuel up top from 5000+ and on the cool days my engine just keeps pulling very hard to about 7800rpm. On hot days it doesn't matter where the timing and fuel are, still have no power :(

Bad news:
Errr!!! Still no RPM switch, not happy. -Cries-

I guess we will have to put this off for now... And I was really exited! Damn :(

On a lighter note this will give a chance to buy the pineapple intake sleeves :) What do you think? I really apologize for the delay. Perhaps we can do Oct 8? Or even a weekend, whatever works best for you. I hope I'm not to much trouble bro.:(

New list of things to buy:
1)Intake Sleeves
2)LIM gasket

Nah, no trouble at all.

Better to have everything while your here instead of making multiple trips.

As long as the day lands on a Monday. I should be getting Monday Tuesday and Wednesday off soon working 4 10 hour days so we will see.

Just picked up another RPM switch on ebay! :) I'll pick up some pills during this month to. Which sizes do recommend getting? Also for the intake sleeves I just need 1)Intake Sleeves 2)LIM gasket, right? :) Thanks bro. Your going to be getting Pizza, Donuts and Bagels ;) lol....

We can throw the Header on too (if we have time) Or I can do it before as well. you can test the car before and after mods to see what the butt dyno says for the power upgrade.

Aux, 3800 and VDI 5200.

You talking about the Pineapple port sleeve inserts? If so then just those. The Series 4 LIM Gasket you don't need for the sleeves but you do need it for UIM and LIM to mate.

PARTY TIME!

The header should be no problem. Afterwards we may need to fool with the pressure sensor since a few times that has caused some issues with people swapping to the s5 intake manifold. With me, I just had to unplug it electronically, drive around, plug it back in and it worked fine. The issue that may come up is power completly dropping off after 5000rpm.

I hope its not to cold when you come up, I have no heat in my barn :)

Nothing runs hotter than a rotary engine, it makes a great heater :icon_tup: :rlaugh:
Nah early oct might be in the upper 60's nice whether, I'll bring hot chocolate and coffee though, hehe.

I dunno, I have ran my car in the barn and it never goes up a degree, although you do start to get a little light headed from the exhaust fumes :)

Just ordered the intake sleeves! :)

You mean the Intake Sleeve Inserts. :)

Nice, Can't wait. Although, its starting to get cold ! Im going to have to clean out my barn and get a propane heater in their soon!

The day draws near! :) Can't wait. Final parts list

1)manifold (all 3 pieces, they have not been separated)
2)RPM switch x 2 MSD
3)ACV gasket
4) Middle manifold gasket
5) EGR Block off plate
6) Sleeve inserts
7) Primary fuel rail

buying from you:
1)Secondary Fuel Rail
2)Summit Rpm Switch
3)Electric Solenoid
4) VDI Actuator.
5) temp MSD pills

Mission 1) VDI 2) Sleeve inserts;
3) Header if there is time...

Weather predicted at a nice cool 66° :)

Other supplies, Bagels, coffee, mountain dew & pizza. ;)

Alright bro, guess I should ask, how much $ for your services/help? Send me a PM on that, so we can work something out. Don't got much (college student lol), but I'm not cheap either ;) Also PM address as well please.

What time would you like to meet?

Correction on the buying list.

No Donuts ??!??!?? You gata be at my house early in the morning! :)

I get up usually around 6am or 7a. It depends when my parrot wakes me up. So somewhere after that.

I'll PM ya the rest. :)

Oops! Forgot about the donuts, those are essential to good project completion! :P

Going to have to get 24 donuts. 3 donuts per hour should be sufficiant :)

Carlos , I spell ur name right?

I will be taking progress pictures and posting them here so you can see aht has been done and how its been done.

With the RPM switches, I will probubly take them apart and just solder the correct resistor inside for the specific activated rpm intead of using the pill. It will be more reliable that way since they will be hidden under the carpet.

I hope to get the parts in soon, thats really all what im waiting for. If I had you get those parts there wouldn't be an issues but thats my fault.

But here are the Port sleeves with inserts :) I love these things !!!! Just remember how they looked before. YIKES.

http://www.midnightgray.net/images/portsleeves.jpg