RotaMan99

I contridicted myself today. But really, its easy when you have everything. Unfortunatly, I missed a few things.

So here the list so no one forgets anything like I did.

1)S5 LIM (S4 LIM if keeping Emmisions), UIM, DC, Throttle Body Spacer (Very Important).
2)S5 Vacuum Rack (Again, Very Important)
3)S5 Thermowax
4)S5 BACV and plug with atleast 6" of harness
5)S5 VDI and AUX Actuators (S4 Actuators if keeping S4 LIM)
6)S5 Air Control Valve (If using stock air pump to activate VDI and AUX)
7)S5 Air Control Valve Gasket
8)S5 Manifold Gaskets (S4 UIM -> LIM Gasket if keeping S4 LIM)
9)S5 Primary and Secondary Fuel Rails
10)New Injector O-rings and grommets.
11)2 New Injector Air Bleeds (Plastic Diffuser, pic below)

12) EGR Block off plate and Gasket (Or RTV)
13)2x MSD Rpm Switches
14) Reuse 2 Electronic Solenoids. FPR and EGR would be best. Using Harness wires and switches at ECU
15)Electric Air Pump(s) (If not using stock air pump)
16)Donuts!!!!!!

All little parts can be purchased from Mazdatrix.com

RotaMan99

Some wiring work.

Fast wiring diagram


And the actual relay box which will help the switches activate the solenoids. I had to do this because the ECU activates the solenoids with 12v+ but the rpm switches activate with Ground so that wouldn't work. The box will activate them with 12v+ now.

The wiring connectors you see were already on the RPM switch. I will remove them, solder longer wires on and heat shrink them.

Rotary_Powerd

I can't believe the difference in those sleeves! Soooo much carbon build up before! Woah nice diagram. Looks good, thanks again for your help, I believe more donuts are in order. Everything looked much better than it was before. (no more seized parts,lol)

RotaMan99

Ya I hope when I do a comp test I get some good numbers since that OMP's control arm was seized.

To night I will be installing the switches and relay box. Going to modify the circuit board a bit so I can mount it in the box, either that or put a small piece of foam or rubber above the relay box to keep it from moving around.

Thursday I can't work on it since im working both my jobs that day and will be tied up all day.

Friday, if I don't have the vacuum rack, I will work on modifying the s4 one to work, run/reroute new vacuum lines and fuel lines and possibly relocate 2 solenoids further toward the drivers side. I can get the S4 TB spacer to work with the S5 LIM. I believe only one vacuum port on the back side will not operate. So I should get it running either Friday morning or Saturday night. See if you can get those fuel injectors parts I PMed you about.

The air bleeds (Pictured in the post above) we should get 2 and also 4 lower grommets, 2 primary and 2 secondary injector grommets, to reduce the possibility of a vacuum leaks. I will PM you more links to those parts.

I can go without donuts, I could be greedy on the other hand

RotaMan99

WIRING IS DONE!!

Need a 5000rpm pill for the VDI switch. 3800 RPM pill installed in the AUX switch. I will label them, AUX switch is on the bottom and the VDI is on the top. I labeled the relays in the relay box as well with the wire color codes.

Now you will be able to use the EGR and FPR solenoid to activate the VDI And AUX ports.

ALL connections have been securley soldered and shrink rapped. No crimp connectors allow on this job.

A mess it looks like but soon will be organized.


Relay box and Switches, 100% wired up.


The finished product.

RotaMan99

The relay box is also setup for a future upgrade to electronic air pumps. I used 10amp relays which means you can hook up 1 or 2 electric air pumps to the same wires as the solenoids.

The only thing I would reccomend is running a wire from the battery or getting power from the main relay, not directly at the ECU. Then hook the new wire up to the relay box. If you hook up air pumps of some sort to the relay box now, that may or may not cause a voltage drop at the ECU at pin 3I which is the ignition power to the ECU. That is where I am getting the power from since the solenoids draw almost nothing.

I will have to do some current testing at the ECU to find out how much current it draws at both 12V+ wires. Unfortunatly, my Multi Meter is in my car that you have

Hope you like the work Friday morning I should have most of the modifications done and saturday I may be able to get it running. If not saturday, 100% on Sunday.

I can make the BACV and Thermowax work but using S5 parts is just much easier. O well.

If you don't know what something is that im talking about just let me know, I will be happy to explain.

Rotary_Powerd

OMG that looks amazing! Soooooo clean!!! wow... I wish I could say more but I'm speechless

I'm super impressed. Oh I ordered the parts from Mazda Trix you said, I told them to directly ship to you via 2day. I'm trying really hard to get you the other parts as fast as possible, I'm waiting for the guy on FC3S to reply. I'll hit up ebay tonight.

RotaMan99

Thanks bud! Took me about 3 hrs to do. I had to reprint my wiring diagram and double check the pin out on the ECU so it actual wiring was probubly around 2.5 hours

So there really was no way to get this done in one day. At first I was only going to put the switches in the engine bay when I first told ya about being done in a day, then I changed my mind.

I miss my car, my truck is eating my money
Next time I do this for someone, remembering how much crap mazda puts in the bay and how many bolts and crap they tie together, I think i'll be charging more, lol. When I did mine, emmisions and about a million other things were already removed so the swap was done in about a day.

Remember when I said I was **** about seeing newly run wires in the engine bay? Same goes for messy wiring.

Don't worry to much about the vacuum rack, TB spacer, BACV or thermowax. I will get everything to work properly and that can be another time. If you pay for that stuff now, I may not get it till monday at the earliest and that is when I gata see ma girl.

So we can wait on that. Still get the parts but no rush, I can make it work with no issues.

The fuel injector parts will be good if I get those on friday or saturday after work but I don't think they deliver on saturdays. We'll see. Again, I can put those in another day, or you could put them in if you wanted to do some work your self. Thats if I don't get them on friday or saturday.

I wrapped the circuit board in electrical tape to make it a little more snug in the box, it just fits without a little tape, added some tape, that thing aint movin

Im going to wrap the new wires a little with e-tape so it looks a lil mo betta

Rotary_Powerd

I'm going to try to have the parts from FC3S shipped out tomorrow via overnight shipping. I'm going to try to get them to you by Saturday. The gentleman gave me a fair price.

RotaMan99

Well I got the S4 Vacuum Rack to work after some modifications. Works pretty slick, there are a few areas I would need to braze and I was going to sand blast it to clean it up. So If the FC3S is shipping a S5 N/A Vacuum rack. GREAT but if I don't get it by Saturday, S4 Vacuum Rack will work fine

I want it running Saturday and be able to drive it and tune / adjust anything on Sunday and get it back to you Monday.

I moved the Alt forward about 1/4" to clear the manifold. Tomarrow I will be moving the BACV Connector to the passenger side. I made a little indent in the secondary rail so the BACV connector can slip on the BACV with ease.

I will be buying some vacuum line, fuel line, hose clamps, and some more heat shrink tubing.

I gata think of what else to do tomarrow since im not going to be putting the manifold on.

Rotary_Powerd

I'm going to reimburse you for any additional supplies as well as some of the gas you've burned going down to the auto store in your pick up. Do you have a paypal address? Or will the old green do in person I have a small gift as well. It's not much but...

RotaMan99

ah ya thanks man. I was actually going to ask you about the burning gas $ but didn't know how to ask for more money and not sound like im greedy I hate asking for more money.

Either will work. Paypal will probubly be better, I wont want to spend th emoney right a way. I'll PM you my paypal address. Im trying to save up for another car, but I just started dental work again so my money is going out the window like its air.

I'll add up what I have spent.

What parts are you getting from FC3S? Vacuum Rack and Throttle Body Spacer?

Rotary_Powerd

[quote name='black89rx7gtus' date='Oct 12 2007, 02:07 PM' post='885279']
hey man i have the thermowax and the s5 vac rack and bacv w/plug. let it all go for 50. dont have the harness tho. have the spacer too.
[/quote]

End up getting stuff from nopistons.

RotaMan99

I did a little more after work. Only about an hour or so. Just replaced the vacuum lines on the oi linjectors to the vacuum manifold but have them routed to the rear of the engine instead of the front. Primary injector air bleed taps off of one of the oil injector vacuum lines.

Replaced a coolant hose on the rear of the engine that goes up to the thermowax and I will also replace, once I get the right 90* part from the store, the coolent line that runs from behind the water pump housing to the BACV.

Made some new gaskets for the AUX actuators. I have to pull the LIM off too remove the old gasket meterial.

RotaMan99

Some updated pictures right before the UIM goes on.




I love how the VDI and AUX activation looks almost stock in the engine bay.

Guess what I found while snooping through my spare parts? S5 TB Spacer

Going to do some more grinding on the S5 UIM now and I will be putting that on. I hope to have it running tonight but if not, it WILL be tomarrow right after work.

Rotary_Powerd

ooooooo looks awesome, Sorry the parts didn't get there in time bro check your email I'm itching to drive my car again

RotaMan99

WAIT THERE IS MORE!



I had to make a new gasket for the VDI and get the VDI free'd up. I don't know who you got it from but they used a thick o-ring instead of a gasket which will only cause stress on the supporting ears. They also installed it backwards

I keep forgetting stuff at the auto store when I go, so I start to work on the car and think I have everything, then I run into an area and smack my self up side the head and ask WHY DID YOU FORGET!!!!!! O well. Its on hold once again till tomarrow.

Rotary_Powerd

-nods- damn sorry man -pretends to know what rotaman is talking about...

You need a hybrid bro... :P Sorry couldn't resist
I'll reimburse you as much as I can bro, you time is like gold for my engine. I'm going to kick myself for all the trouble this is causing

RotaMan99

hahaha. I know I was going to add some statement saying "like you know what im talking about" haha.

Nah no trouble at all. The car was not maintained very well by the previous owner so a little reworking is in order but it should be good soon. I would do a full tune up though sometime maybe spring of next year.

HAHA. Ya I hate those things! I will pay for my gas instead of driving them!!! We'll be even with the $10 for gas bud. I usually stop at the auto store on my way home from work so its not that far out of the way. I just wait till the next day to stop by next time

Rotary_Powerd

It hurts me that my car wasn't loved much before I had it. I feel so naive thinking my car was in decent mechanical condition I did all the fluids recently, so I'll get some new spark plug wires, and brakes + lines as soon as I can afford it

RotaMan99

You can scratch vacuum lines and intake gaskets off the list of things to do

I will make you a list of stuff that should see attention soon.

Rotary_Powerd

The 16 hours count down begins lol.

Rotary_Powerd

Thanks man got home in one piece lol.