irvined
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| posted on 10/6/05 at 09:19 AM |
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Mazda MX5 engine removal/refitting
Hello,
I'm having a bad car week. My mk1 1.6mx5 decided to go bang, so this weekend im removing the engine and fitting a replacement.
Unfortunately I've not had the car long enough to get a haynes manual/workshop manual its currently 'in the post' grr.
Has anybody done this before and is there anything I should watch out for before I start unscrewing things?
Cheers
David
http://irvined.blogspot.com
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JAG
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| posted on 10/6/05 at 09:34 AM |
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Obviously I have had some experience with this engine (see my photo archive).
The only thing is it was fitting this engine not removing it 
The only comment I would make is be gentle with the airflow meter (it's in the intake ducting on top of the air filter) as it is easy to damage
this part. This very problem stopped my engine from starting when I first fitted it.
Also be carefull with the water temp' sensor (in the top of the thermostat housing) as it is very easy to catch it and snap off the top.
Other than that just be careful and don't hurt yourself  in the process. Do you have a good engine hoist/crane etc...
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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MikeR
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| posted on 10/6/05 at 10:44 AM |
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No, he's got my engine crane + leveller 
along with my drive, garage, house keys ..... so no parties while i'm out!
Does anyone know anything to watch out for when removing the engine - thinking things like hydralic lines that have to be disconnected / radiator
removed etc.
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JAG
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| posted on 10/6/05 at 11:39 AM |
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Beware of;
heater hoses - at the back of the cylinder head and run into the bulkhead.
Hydraulic clutch hose
Fuel hoses to fuel rail
Hose from intake manifold to carbon can solenoid on drivers side inner wing
Air-con plumbing to air-con pump (if you have air-con)
Power steering plumbing to power steering pump
That's all the stuff I can think of - but then there's the wiring for the sensors etc...
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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NS Dev
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| posted on 10/6/05 at 12:13 PM |
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any ideas what the trouble is yet Mike/Dave????
it didn't sound good over the phone, I presume lifting the head has told you nothing then??
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MikeR
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| posted on 10/6/05 at 03:35 PM |
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Its been to a mazda specialist ....... new engine is the reconmendation as its easier than trying to fix it.
hence car at mine and david making an early morning dash to Douglas Valley Sports Car Breakers J27 M6.
Once the replacement engine is in, i'm sure the old engine will be examined very throughly.
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12a RX-7
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| posted on 10/6/05 at 07:55 PM |
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what are the symptoms ? Mazda BP engines are bullet proof in standard form.
But the early ones do have a habit of loosing the woodruf key on the crank 
[Edited on 10/6/05 by 12a RX-7]
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MikeR
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| posted on 11/6/05 at 09:55 AM |
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lets put it this way, when it was started and i was stood next to it my reaction was as follows......
1) step back,
2) pull face as if its just been suggested i've got two choices in life, slit my wrists or marry a big brother contestant.
3) ask david to stop before the neighbours worry what the hell is going on.
It makes a LOUD da-da-da-da noise in time with the engine. Imagine getting two bits of metal and hitting them in time with the engine - thats the
noise.
Current progress is junk food in my kitchen, MX-5 lifted up on one side, bits over my rear lawn, engine still in car, David (i hope) on his way back
from the breakers.
(the git phoned me by accident at 6:23am!)
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MikeR
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| posted on 11/6/05 at 12:57 PM |
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Progress update........
David is back, engine in the van, engine almost out of the mx-5 (i keep hearing loud metalic bangs).
Well i'm off out - another progress report when i get back around midnight!
(yes i do feel guilty not helping him)
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irvined
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| posted on 13/6/05 at 10:53 AM |
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Well,
It now works, well more or less, there seems to be something funky going on with the electrickery. High up the revs its fine, between 2000 an 3000rpm
it misfires and hesitates a bit and does some wierd things.
I suspect I need to get the ECU checked out and find out what its complaining about, but apart from a broken rad when i took the hose off, and some
real ball ache getting it back into the engine mounts, it wasnt quite as traumatic as I was expecting.
Cheers
D
http://irvined.blogspot.com
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NS Dev
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| posted on 13/6/05 at 11:01 AM |
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has it got a crank sensor inside the sump/block?
If so, take it out and clean the end of it, could be this as the engine will have been shaken about it could have put bits of metal (from the oil) on
the end of the sensor, which makes them do funny things.
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JAG
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| posted on 13/6/05 at 12:58 PM |
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Check out this page for diagnostic info;
http://www.mx5club.org.nz/maintenance/engine_diagnostics/
and this page for a wiring diagram of the engine control system;
http://www.cmr.uq.edu.au/~rotor/the_shed/jpg/b6-ecu.png
I can vouch for all this info' as it was instrumental in getting my MX5 engine back up and running after installation in my Locost.
There is no crank sensor on this engine, the same function is fulfilled by the camshaft position sensor. Which, as the name implies, is located on the
back of the intake camshaft and it's pretty well sealed from the outside world.
Edited to say the engine wiring diagram above calls the camshaft position sensor a 'crank angle sensor' but it's located on the end
of the intake camshaft as I said above  and can be removed from the top of the engine without removing any other part.
[Edited on 13/6/05 by JAG]
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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irvined
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| posted on 14/6/05 at 01:57 PM |
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Hmm, and I also have a water leak, no idea where its coming from... its not the rad hoses as they are definatly sealed now, was dripping from crank
pully area.
Ho Hum.....
D
http://irvined.blogspot.com
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NS Dev
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| posted on 14/6/05 at 03:00 PM |
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water pump!
again not at all uncommon on an engine that has stood for a bit with no water in it, the corrosion creeps under the seal on the pump shaft and
knackers the seal, my vauxhall engines have done it several times.
no use now but I always squirt a load of wd40 into the pump towards the seal if the engine is being left without water in it for a bit.
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JAG
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| posted on 20/6/05 at 08:00 AM |
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Did you discover what was wrong with the engine that you removed?
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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MikeR
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| posted on 20/6/05 at 08:20 AM |
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you mean apart from the very loud "bang bang bang bang" sound it made every revolution
yeah, think he did figure it out, he let is misses drive the car ..........
(boy am i in trouble the next time she sees me )
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irvined
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| posted on 20/6/05 at 08:23 AM |
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quote:
Originally posted by JAG
Did you discover what was wrong with the engine that you removed?
Not yet, hopefully over the next week i'll get around to stripping it down.
www.irvined.co.uk/noise.avi if you want to hear the death rattle.
Will put on a new cambelt, water pump and interrogate the ECU this weekend, (Thanks for the link.) hopefully it will be something silly.
Cheers
David
http://irvined.blogspot.com
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irvined
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| posted on 20/6/05 at 08:24 AM |
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quote:
Originally posted by MikeR
you mean apart from the very loud "bang bang bang bang" sound it made every revolution
yeah, think he did figure it out, he let is misses drive the car ..........
(boy am i in trouble the next time she sees me )
So mike, whats it worth to make sure she doesnt happen to come accross your posting
http://irvined.blogspot.com
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MikeR
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| posted on 20/6/05 at 08:26 AM |
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nothing - i'll enjoy the beeting
actually, i've just remembered how hard she punches ........ errrm....... invite to a bbq end of august ?
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Bob C
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| posted on 20/6/05 at 11:35 AM |
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Just a thought - the old 1.6 mx5 engine has hydraulic tappets - if one of these empties while it's stood it Does make a god-awful racket on
startup. Which can continue for a few minutes. But it fixes itself (though it's worth a couple of flushes & some fully synth to stop it
doing it regularly). From the sound of it yours was worse than this, but it would be a great shame to do a lot of work for nothing.... My old '5
did this once & it was quite an alarming noise - until it completely disappeared.
Bob C
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JAG
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| posted on 20/6/05 at 12:35 PM |
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So Dave,
is the plan to rebuild this engine into a fully working unit?
I was hoping you might break it and sell me some parts
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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irvined
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| posted on 20/6/05 at 02:53 PM |
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quote:
Originally posted by JAG
So Dave,
is the plan to rebuild this engine into a fully working unit?
I was hoping you might break it and sell me some parts
The master plan at the moment is just to find out what went wrong and then break it, unless of course its in near perfect condition in which case i
may tart it up and swap it back in, and sell the replacement, i suspect I'll break it though.
I primarily want to get the one in the car working 100% before i sell anything though.
What bits do you need?
D
http://irvined.blogspot.com
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JAG
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| posted on 20/6/05 at 03:48 PM |
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I'm after a sump and it's more of a 'want' than a 'need'
Have you had time to have a look at the new engine since you installed it? Did the ECU tell you anything?
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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irvined
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| posted on 24/6/05 at 09:26 AM |
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Well accordnig to my flashy light and some voodoo magic, its the TPS, whcih would be consistant with me bashing it abit when i put the engine in.
Looks like i'll be doing some fiddling over the weekend.
Cheerio
d
http://irvined.blogspot.com
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irvined
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| posted on 8/7/05 at 06:05 PM |
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Argh!
Well,
Hasnt it been a fun week, so yesterday headed off to derby from leamington, got about as far as stoneleigh and noticed the temp guage had moved
slightly over from where it normally stays, backed off as I had been caning it, temp went down, debated turning back and decided i was just being
paranoid.
At the back of my mind this whole time of course was the water leak thats been embarassing me whenever i park anywhere.
Nevertheless staying below 80 kept it just slightly hot, but not too hot and i arrived at derby for a bollocking about using my phone in the data
center yada yada yada.
So got back in, topped up the water and off i went down the m1, came up a hill and noticed the temp guage going up, and up, and up, backed off, slowed
down, and up, and up....
Bollocks.
Pulled over, had a shifty under the bnnet, noticed that there was no water in the system. Smeg, waited about an hour (Fixed the radio, and the boot
hinge.) then added some more water, thing is, it didnt fill up, then i realised my car was peeing itself, (Perhaps it was scared of the pounding it
was going to get when it was sorted out.)
It then dawned on me that I hadnt been able to register with the AA the previous night due to their system being down, never mind, i'll give
them a call, system was down again, oh dear.
Phoned RAC, of course you can only get a tow off the motorway and they want payment for a year in advance, they had me by the nads so i caughed up and
the bloke took me to leicester somewhere.
Fortunatly, as i had booked this afternoon off to fix all the annoying but not yet life threatening problems i have with the car. In the boot was a
replacement cam belt, water pump, however in my wisdom, id taken all my tools out to make some space for the servers i was bringing back. Arse.
So miker turned up with some tools, (He forgot the prozac.) and in about 4 hours we'd change the cam belt, (Was a bit hairy when my tactic of
marking up the old belt and cams so it would be a doddle putting it back together nearly failed due to the marker pen not being very good at
marking.)
Nevertheless without getting too wet, or losing too much blood, it burst into life, and is to this moment still continent.
Only problem is, its still overheating, ARSE!
So much for a fun bulletproof runaround till I get the cheap fragile sports car on the road.
So, if anybody has an MX5 with a dodgy water pump, remember, always carry a tin of tip-ex, spare belts, a big knife, a contortionist, and plenty of
spare 12/14/10mm sockets, and you'll be fine
Cheerio
David
http://irvined.blogspot.com
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