The engine swap thread...

**kenholland** · 5-8-04, 17:14

Hi all,

I've been looking through Haynes and other sources and have come up with a check list of things I need for the engine change. Feel free to add any suggestions of ones I've missed:

Engine oil & filter
Cam and drive belts
Gearbox oil
Manifold gasket sets (I may as well keep the shiny covers?)
Water pump
Coolant
High temp grease
Plenty of old blankets and rags
Plastic bags for bits
Sticky labels to mark up connections, hoses etc before removal.
Digicam to take plenty of snaps of what it should look like.

Laptop to see what it should look like when we're putting it back together

Possibly new clutch plates (can I get an uprated one in time?)
Possibly MX3 flywheel

Apparently, the aircon will need refilling after the swap as we have to remove the compressor or pipes, so I better look for someone who can do that locally too.

Oh, and plenty of beer indoors for the evenings...

**xedos 6** · 5-8-04, 17:48

First and foremost Positive thinking ken

axle stands better bolt access with wheels off

Engine hoist check lump weight ? height in book before getting plus chain not washing line

klye with a hoist hmmmmmmm

BIG hammer soft faced + wd40 lots

beg borrow steal good selection of spanners, sockets ect ther more the merrier

Swafega its dirty down there

access to transport for that vital thing missing on the day... bus does not count

Not forgeting sunshine on the day if outside

more

club film possibly to sell of course

Roland

**Einstein** · 5-8-04, 17:51

Right... here's what the bible says... in brief..

Release fuel pressure
drain engine and gearbox oil
jack up front of car
remove front wheels
plastic covers underneath and sides
fresh air duct
air filterbox
battery and carrier
accelerator cable
radiator hoses
cooling fan connectors
radiator and fans
drive belts
p/s pump (don't remove hoses) no need to bleed or top up
a/c compressor (don't remove hoses) no need to recharge, save £££'s
cruise control actuator
Electrical connectors
fuel and heater hoses
clutch release cylinder
transverse crossmember
exhaust pipe
shift control rod (gearbox)
extension bar (gearbox)
tie rod ends (balljoints)
bottom ball joints
driveshafts
engine mounts
engine mount member
finally, engine and gearbox up

Pictures are available, but not really in great detail... and Kyle will breeze this anyway.

John

Chastiser · 5-8-04, 18:41

dont forget the plasters and swearbox(grin) - good luck.

Mike

**xedos 6** · 5-8-04, 19:15

OK here's some more defo's
Trolley jack
Timing light
Ball joint splitter
Thrust bearing kit if replacing clutch poss clutch mandrel
All fluids including more

Mole grips
Access to vice

Not essential but handy to have about ..be prepared motto comes into play
Tap & die set or thread cleaner rod
Circlip pliers external & internal
degreaser
Loctite
Pry bar
Multi meter
Selection of nuts bolts washers on hand ( metric)
Cable ties / electrical crimp / connectors
solder gun if required

Will post more if old brain allows

John your engine list...it won,t come out with the earthing strap connected

roland

Chastiser · 5-8-04, 21:33

Access to vice

i wouldnt have thought that ken would have had access to the internet while changing the engine(grin).

Mike

**Einstein** · 5-9-04, 4:52

And I think no 17 will cover the earthing strap

(sort of)

John

**pro-kart** · 5-9-04, 6:06

ken looks like everyone has thought of most things, but if you need anything out towards my area yeovil just let me know and i'll help get what ever ,,,,good luck mate adrian

**cruisemad** · 5-9-04, 6:09

never looked at it like that.

Ive done it that many times now i dont mark up connections cause all electrics only fit one way anyway!!! As for coolant you only need to disconnect 4 hoses.

The way i normally do it is to take both cross members off and get everything off underneath first including drive shafts and then get to work on top. As ive said my record for one out (with a buzz gun) is about 1 hour 30min on me todd!!! Without and just my trusty ratchet for company its nearer 3-4.

You dont need power steering fluid as its easier to leave the pump on the car. Trust me on that one.

**cruisemad** · 5-9-04, 6:20

ken if you can get an mx3 flywheel now is the time. Speak to mazdaspares as they are always breaking engines and saved me when i needed 1 yes 1 ze cam and my flywheel.

As for clutch its a good idea but you wont get an uprated on in time. If its ok leave it for now and get an uprated one later.

Kyle

**wolf_funk** · 5-9-04, 6:54

u going live via web cam for this engine swap ken? lol

**wolf_funk** · 5-9-04, 6:55

have u got a sky hook for this one?

**Einstein** · 5-9-04, 7:02

Can't do a live transmission on this.. no way....

Just think what would happen if Roland got hold of it..

&^*%*

"The party before Japfest 2, (the nightmare begins)"

John

**kenholland** · 5-9-04, 10:50

LOL all.

Been busy today - here's where I'm up to:
Car jacked, chocked and on axle stands.
Fuel pressure relieved (the squirty way when I removed the FSE)
CAI etc all removed back to the TB.
Battery and tray out.
Engine drained (it was mostly coolant). Gearbox still to do.
Splash guards off from underneath.
Coolant drained (what there was!)
Hoses off, rad out, fans out (in that order 'cos the aircon pipe is in the way)
Fuel and heater hoses off.
Accelerator cable off.
Wiring nearly all off with plenty of photos as I went and sticky labels on lots of connectors. I'm stuck on one small spade connector rear bottom left which I just can't get off at the moment...
Swear box full, plasters all used up.
I've left the wheels on for now 'cos I don't want some pikey nicking my discs.

Dunno how the heck Cruise managed an hour and a half - it's taken from 10am to 3pm for me to get this far!

I'm checking on a couple of engine warranties, what's included etc tommorrow and all being well will order then - should be delivered this week. I'll also get hold of MazdaSpares to see if they have a flywheel. And Magna Mazda to order up belts, gaskets, oil filter etc.

Right now it's time for a long soak to ease me old bones.

Cheers,
Ken

(I'm surprised I haven't had a PM from Roland asking for the address so he can come and film the lift.

)

**Ian F Chequer** · 5-9-04, 11:21

You will need one of these to do up new bolts to the required torque. I have a Halfords Professional job which will pull up to 200 NM.

For getting nuts and bolts undone which are determined otherwise a breaker bar (the biggest you can get your hands on and 1/2" drive) and a plumbers / Stillson wrench. These will work even on fasteners which are really rounded off.

At some point you will need to support the weight on the engine on a jack placed under the oil pan so make sure you have a spare jack and a big lump of wood to spread the weight on the pan. I know it sounds trivial but not everyone has wood lying about.

I have all of these so if you need a hand let us know.

regards,

Ian Chequer

5-8-04, 17:14	#1 (permalink)
kenholland Ex-Mod Join Date: Dec 2002 Location: Dorset, UK iTrader: (0)	The engine swap thread... Hi all, I've been looking through Haynes and other sources and have come up with a check list of things I need for the engine change. Feel free to add any suggestions of ones I've missed: Engine oil & filter Cam and drive belts Gearbox oil Manifold gasket sets (I may as well keep the shiny covers?) Water pump Coolant High temp grease Plenty of old blankets and rags Plastic bags for bits Sticky labels to mark up connections, hoses etc before removal. Digicam to take plenty of snaps of what it should look like. Laptop to see what it should look like when we're putting it back together Possibly new clutch plates (can I get an uprated one in time?) Possibly MX3 flywheel Apparently, the aircon will need refilling after the swap as we have to remove the compressor or pipes, so I better look for someone who can do that locally too. Oh, and plenty of beer indoors for the evenings...
	Ken

5-8-04, 17:48	#2 (permalink)
xedos 6 Join Date: Jun 2002 Location: Poole Dorset UK Age: 53 iTrader: (0)	First and foremost Positive thinking ken axle stands better bolt access with wheels off Engine hoist check lump weight ? height in book before getting plus chain not washing line klye with a hoist hmmmmmmm BIG hammer soft faced + wd40 lots beg borrow steal good selection of spanners, sockets ect ther more the merrier Swafega its dirty down there access to transport for that vital thing missing on the day... bus does not count Not forgeting sunshine on the day if outside more club film possibly to sell of course Roland
	Why mod when you drive Perfection UK Engine Swap Team Member if you can find us - you can hire us

5-8-04, 19:15	#5 (permalink)
xedos 6 Join Date: Jun 2002 Location: Poole Dorset UK Age: 53 iTrader: (0)	OK here's some more defo's Trolley jack Timing light Ball joint splitter Thrust bearing kit if replacing clutch poss clutch mandrel All fluids including more Mole grips Access to vice Not essential but handy to have about ..be prepared motto comes into play Tap & die set or thread cleaner rod Circlip pliers external & internal degreaser Loctite Pry bar Multi meter Selection of nuts bolts washers on hand ( metric) Cable ties / electrical crimp / connectors solder gun if required Will post more if old brain allows John your engine list...it won,t come out with the earthing strap connected roland
	Why mod when you drive Perfection UK Engine Swap Team Member if you can find us - you can hire us

5-9-04, 6:09	#9 (permalink)
cruisemad Join Date: Feb 2002 Location: Chester, UK Age: 28 iTrader: (0)	never looked at it like that. Ive done it that many times now i dont mark up connections cause all electrics only fit one way anyway!!! As for coolant you only need to disconnect 4 hoses. The way i normally do it is to take both cross members off and get everything off underneath first including drive shafts and then get to work on top. As ive said my record for one out (with a buzz gun) is about 1 hour 30min on me todd!!! Without and just my trusty ratchet for company its nearer 3-4. You dont need power steering fluid as its easier to leave the pump on the car. Trust me on that one.
	MEMBER OF THE YEAR 2005 THEY SAY LIGHTNING NEVER STRIKES TWICE.. TRUST ME IT DOES... AKA CLUTCHMEISTER

5-9-04, 6:20	#10 (permalink)
cruisemad Join Date: Feb 2002 Location: Chester, UK Age: 28 iTrader: (0)	ken if you can get an mx3 flywheel now is the time. Speak to mazdaspares as they are always breaking engines and saved me when i needed 1 yes 1 ze cam and my flywheel. As for clutch its a good idea but you wont get an uprated on in time. If its ok leave it for now and get an uprated one later. Kyle
	MEMBER OF THE YEAR 2005 THEY SAY LIGHTNING NEVER STRIKES TWICE.. TRUST ME IT DOES... AKA CLUTCHMEISTER

5-8-04, 18:41	#4 (permalink)
Chastiser Banned Join Date: Jul 2002 Location: Hemel Hempstead, UK Age: 50 iTrader: (0)	dont forget the plasters and swearbox(grin) - good luck. Mike

5-8-04, 21:33	#6 (permalink)
Chastiser Banned Join Date: Jul 2002 Location: Hemel Hempstead, UK Age: 50 iTrader: (0)	Access to vice i wouldnt have thought that ken would have had access to the internet while changing the engine(grin). Mike

5-9-04, 6:06	#8 (permalink)
pro-kart Join Date: Feb 2002 Location: somerset,uk, UK iTrader: (0)	ken looks like everyone has thought of most things, but if you need anything out towards my area yeovil just let me know and i'll help get what ever ,,,,good luck mate adrian

5-9-04, 6:54	#11 (permalink)
wolf_funk Join Date: Oct 2003 Location: NEW YORK, NY, USA Age: 40 iTrader: (0)	u going live via web cam for this engine swap ken? lol
	http://www.cardomain.com/id/wolf_funk MODS: Racex Performance Chrome Filter, mazdaspeed sunvisor, . tinted back lights, leather seats duel fog light. . rear facing camera. . Have TOYO Proxies fitted. NOW HAVE EAGLE TALON CAI STAINLESS STEEL CATBACK TINTED WINDOWS

5-9-04, 6:55	#12 (permalink)
wolf_funk Join Date: Oct 2003 Location: NEW YORK, NY, USA Age: 40 iTrader: (0)	have u got a sky hook for this one?
	http://www.cardomain.com/id/wolf_funk MODS: Racex Performance Chrome Filter, mazdaspeed sunvisor, . tinted back lights, leather seats duel fog light. . rear facing camera. . Have TOYO Proxies fitted. NOW HAVE EAGLE TALON CAI STAINLESS STEEL CATBACK TINTED WINDOWS

5-9-04, 10:50	#14 (permalink)
kenholland Ex-Mod Join Date: Dec 2002 Location: Dorset, UK iTrader: (0)	LOL all. Been busy today - here's where I'm up to: Car jacked, chocked and on axle stands. Fuel pressure relieved (the squirty way when I removed the FSE) CAI etc all removed back to the TB. Battery and tray out. Engine drained (it was mostly coolant). Gearbox still to do. Splash guards off from underneath. Coolant drained (what there was!) Hoses off, rad out, fans out (in that order 'cos the aircon pipe is in the way) Fuel and heater hoses off. Accelerator cable off. Wiring nearly all off with plenty of photos as I went and sticky labels on lots of connectors. I'm stuck on one small spade connector rear bottom left which I just can't get off at the moment... Swear box full, plasters all used up. I've left the wheels on for now 'cos I don't want some pikey nicking my discs. Dunno how the heck Cruise managed an hour and a half - it's taken from 10am to 3pm for me to get this far! I'm checking on a couple of engine warranties, what's included etc tommorrow and all being well will order then - should be delivered this week. I'll also get hold of MazdaSpares to see if they have a flywheel. And Magna Mazda to order up belts, gaskets, oil filter etc. Right now it's time for a long soak to ease me old bones. Cheers, Ken (I'm surprised I haven't had a PM from Roland asking for the address so he can come and film the lift. )
	Ken

5-9-04, 11:21	#15 (permalink)
Ian F Chequer Join Date: Nov 2003 Location: Kirkintilloch, near Glasgow, UK Age: 35 iTrader: (0)	torque wrench You will need one of these to do up new bolts to the required torque. I have a Halfords Professional job which will pull up to 200 NM. For getting nuts and bolts undone which are determined otherwise a breaker bar (the biggest you can get your hands on and 1/2" drive) and a plumbers / Stillson wrench. These will work even on fasteners which are really rounded off. At some point you will need to support the weight on the engine on a jack placed under the oil pan so make sure you have a spare jack and a big lump of wood to spread the weight on the pan. I know it sounds trivial but not everyone has wood lying about. I have all of these so if you need a hand let us know. regards, Ian Chequer
	Four Triple Two - 198901 miles on original powertrain. Last seen standing in line for the crusher. Forgiven - maybe Forgotten - not likely