Help please folks.

[Parallex]

Hi guys.

Does anyone have a picture of a transplanted ZE in-situ? Basically I need to know what the vacuum pipes look like at the back. I have read the write up, and although helpful, it doesn't have pictures any more.

I am trying to get my ZE sorted for the weekend!

Ben.

[Russellg]

Ken has a couple of pics on his web page.
Don't know how usefull they'll be.

Previous CarsnBikes

Russ

[Parallex]

Thanks for that mate. Those pics at least provide a small clue or two.

I have got the Ze into my engine bay now - which systems need bleeding?

When I did the change, all of the fluid systems were exposed, and leaking. Can anyone give me any tips?

Ben.

[mazdamatt]

obviously dont connect the egr ones

[Parallex]

Guys I am having real trouble with this. I am worried I wont get it all done before Saturday. The wiring loom is proving a pig to get back in, and the vacuum pipework is impossible. I have the vacuum pipework worked out up until the vacuum source bit. The way MazdaMatt has it setup is weird - the vacuum source behind the throttlebody is not being used? WTF?

Also, does anyone have any tips with the wiring loom? There are soooo many plugs that seem to have no purpose on a ZE.

If someone can help please PM me your phone number so I can call you otherwise I won't be able to bring the car I have worked so hard on to Japfest.

Ben.

[fredio54]

Have you posted it in the appropriate forum as well as here? Put one in 2g other perf or 2g general and see what happens?

Are you sure the purposeless plugs had a purpose on the DE ?

Looms are built for max spec and not all cars use all plugs. My ute has all the loom for the efi version, but no efi. plug for float in brake reservoir and no float switch etc...

Did you label them one by one as you took them off the DE ?

[Oddball]

Help with the VRIS Ben ...






The above pic shows how to convert DE to ZE, in which case, A = no longer needed, B = as A is not needed, connect other vris straight to here, C = this metal pipe becomes redundant, can stay unconnected, D= can remember why i put that in .. Anyways .. anything RED is not needed for a ZE vac set-up .. and all the RED sections are to do with the EGR.

In the first picture you will see that i have probably answered your Q on the vac source behind the throttle body...

As for the wiring loom, remember you do not have the egr solenoids to connect to, thats 2 redundant plugs straight away.

Paul.

[Oddball]

Oh look .. a wiring loom pic too ...

[Parallex]

Paul - You are either god or a very great fellow. Thankyou from the bottom of my heart - with these excellent diagrams and that photo, my task has been reduced in complexity by a factor of ten.

This may be worth making a sticky about - as people often have trouble with this.

Ben.

[Parallex]

Right - We have got most of the wiring connected up, with all of the pipework sorted out and connected up. I think the VRIS vacuum lines are all done in the right fashion.

We are going to be putting the intake and everything else in tomorrow, as well as the subframes and front engine mount etc. Hopefully she will start first time.

Ben.

[Parallex]

Guys - URGENT - I don't have much time.

My J-Spec distributor has only one plug on top, and I don't have any plugs that fit it on my loom - what do I do?

Ben.

[Oddball]

Use your original distributor Ben, the ZE distributor has an external coil, so you have no chance of using that unless you have a ZE loom.

Paul.

[Parallex]

Cheers Paul.

We have got her in and she is running. However, we cant change gear when the car is switched on, the idle is lumpy and seems to die when throttle is let off. What am I doing wrong? We are thinking there is vacuum issues somewhere. But that doesn't explain the gearbox does it?

Ben.

[Oddball]

Just spoken to Ben, looks like the gearbox is going to have to come out and sort the thrust release bearing.. something wrong there as there is free movement on the release arm and no compression.

Paul.

[Parallex]

Hey guys.

Looks like my 6 isn't going to be coming to Japfest! The gearchange just doesn't happen, and there are a couple of other issues that I think should really be sorted before I go driving it any distance.

Basically, there are two options that I can choose from in terms of what I have done wrong in the engine change.

1) The thrust bearing has been put on wrong. Not good.
2) The clutch plate has been put on the wrong way round. (I didn't think this was possible as I thought the box wouldn't go together with the clutch plate in wrongly.)

I tested the theory behind this by switching the engine on (lumpy as hell & hunting), and then trying to get it into gear. Even without the clutch depressed, the engine would start dieing if I moved the gearstick near to a gear notch. This means that clearly the gear mechanism is fouling the driveshafts / crankshaft. Not good. I am such a muppet - I can't believe I have done this.

Oh, on a last note, how do I stop the fan from being on constantly? I'm not sure why it is, as I have the water temp sensors in etc.

Ben.