Project: 1995 Miata

[JPolen01]

Someone start it already.

[Jake]

Another big day today. As always, my friends are the best for helping power through all of this.

Started the day by dropping the transmission, which is harder than it sounds. The stock exhaust has a separate downpipe, but my headers have the downpipe welded on. So, we had to work around it. Dropping the trans includes...

* Remove coil pack and cam angle sensor
* Unbolt headers from block, while working around heater hoses and hard coolant line. Leak coolant everywhere.
* Disconnect upper radiator hose. Leak coolant everywhere.
* Loosen motor mounts
* Jack up front of motor, but not too much
* Wedge trans around everything

Anyway, it was a pain in the ass.

Come to find out, the clutch was installed properly the entire time. However! I suspect the throwout bearing was improperly installed the first time. It fell into the bell housing as we dropped the transmission, so it likely wasn't secured well (if at all).

So, we got the trans back in. Had to drill out two studs from the catalytic converter (they stripped) and replace with nut/bolt combo. Reinstalled exhaust and driveshaft, and lo and behold, it moves!



Joey and I took it for a tank of gas and Wendy's. Some observations:

* Scary vibration/rattle at idle. Need to check motor mount torque. Probably not tight enough.
* Need to adjust clutch pedal travel. It engages too high up (Goodspeed and I fooled with it, so it's expected)
* Check engine light comes on after 2.5 miles of driving. It's OBD I so easy to jump the diagnostic pins and have it blink the code at me.

I have new tie rods coming this week, so I'll need to install those (current ones are shot) and take it for an alignment.

Even with the rattles and scary bits, it felt SO GOOD to be behind the wheel of my car tonight. Huge, huge thanks to everyone who helped rebuild her.

[Sully]

At least you have friends to help. I put the civic trans back in yesterday by myself and couldn't get a jack in there for several reasons including some stupid aftermarket cross member that would have been more of a pain to drop so I had to lean over the fender and lift it in through the bay. It was not fun.

Glad to hear this thing should be back to 100% soon. Or 78% like most of us keep our projects.

Sent from my DROID RAZR using Tapatalk 2

[Jake]

Yesterday was another big day of Miata, but this involved more cleaning and shakedown than repairs.



Joey and I degreased the garage floor, which was very necessary after spilling oil, coolant, fuel and trans fluid all over it. Then we degreased the car, which was necessary after spilling oil, coolant, fuel and trans fluid all over it. The paint is kinda-shit but a good claybar and polish would help out a lot. Front bumper needs a re-spray to look good again.

After that, we drove it. Put 35 miles on it all around the back roads of Clifton and learned some things. Here's everything I have left to do:

1. The catalytic converter was attached by three bolts, as the nut for the fourth stud wouldn't thread on properly. Pretty sure the other three buts have backed out a little bit. The car sounds like a Spec Miata. It's embarrassingly loud. Need to jack it up and tighten/install fourth nut.

2. I think I forgot to re-hang the rear-most exhaust hanger. That, plus the partially-disconnected cat, are probably what create this awful vibration/buzzing at idle.

3. Throttle cable stuck partially open by coming off the bracket. Had not tightened the nut holding the cable to the bracket down enough. Need to tighten with wrench. Used fingers to fix because that's all we had in the middle of nowhere.

4. Random wisps of smoke from rear of engine, near firewall. Doesn't smell like anything, seemed to go away after some driving. We spilled a LOT of coolant back there, and my best guess is that it's just steaming off a bit.

5. Check Engine light comes on after the motor reaches operating temp. I jumpered the diagnostic pins (thank you, OBD I) and am getting three different codes. Assuming I'm reading them right, they're 4, 6 and 9. The fault code page at Miata.net does not acknowledge the existence of code 6. I need to do some sleuthing on this one, but the car runs fine right now so it's not an immediate concern.

6. Airbag light is blinking. I need to remove the driver's airbag and actually solder the wiring together. The car has an NB wheel, so I had to splice wires back when I installed it. This involved my favorite method known as "twist and tape" - methinks the twist has loosened.

7. Radio sucks as usual. I need a head unit with a simple aux input. Current H/U has the "old" iPod connector (30 pin) and I have an iPhone 5, so the plugs aren't compatible. If anyone has a head unit that they'd donate to the cause, or sell for cheap (like $20), let me know. I have new speakers to throw in the doors if need be, too.

8. Tie rods are on their way and will be installed soon. Alignment comes with that.

Basically, the car runs really damn well, given the fresh swap. Just needs to have some bolts tightened/checked and other little things tweaked.

It was THE greatest feeling to drive around yesterday, even with the problems.

[Jeff]

I have a radio I am tired of looking at. I would rather not sell it at this point just trade it for something. Anything you are looking to get rid of I might want? I paid a TON of money for it many years ago so actually selling it would make my butt hurt.

[Jake]

I have a radio I am tired of looking at. I would rather not sell it at this point just trade it for something. Anything you are looking to get rid of I might want? I paid a TON of money for it many years ago so actually selling it would make my butt hurt.

PM incoming.

[SlimKlim]

This accurately summarizes my life in one picture.

Also, fun fact, Matt Bralley is actually in this photo.

[Kaan]

is that his foot or is he just under the car?

[SlimKlim]

Oh, the foot belongs to Sasha. I believe Bralley is fighting with the bell housing bolts in that picture, don't really remember what stage we were in. I think I'm reinstalling the CAS and coil pack

[xvxax]

Ah yes, the feeling of the first test drive after a big project like that. Great feeling. I also recognize that road. One of my personal test drive stomping grounds.

So how does the power feel? What kind of numbers do you expect? Will you be dusting LS1 powered m3 sedans in the uphill esses now or what?

[SlimKlim]

I believe he is currently commuting home so I'll take this one.

So how does the power feel? What kind of numbers do you expect?

Our scientific analysis yesterday determined its more powerful than the dying motor but maybe still not all there. Maybe because the exhaust wasn't hooked up past the downpipe and we were losing a bit too much backpressure, maybe it still has some vacuum leaks, or maybe we just forgot how slow an NA Miata really is with 2 dudes in it.

The new motor puts out 140hp, maybe a smidge more with the intake/exhaust.

Will you be dusting LS1 powered m3 sedans in the uphill esses now or what?

Provided they forget how to accelerate it'll blow the doors of 'em. :thumbup:

I've already tried to plant the seed of turboing it next year, I'm doing what I can.

[Jake]

Ah yes, the feeling of the first test drive after a big project like that. Great feeling. I also recognize that road. One of my personal test drive stomping grounds.

So how does the power feel? What kind of numbers do you expect? Will you be dusting LS1 powered m3 sedans in the uphill esses now or what?

Joey summed it up pretty well. I gotta hook the rest of the exhaust back up before passing judgement. And yes, a Miata with two dudes in it is still 1) really slow and 2) macho as fuck.

I'd guess the new motor is putting out ~150 hp. Old one (when new) had 128 hp. I'm really curious to see what this will dyno at when it's all said and done.

[JustinG]

I'd guess the new motor is putting out ~150 hp. Old one (when new) had 128 hp. I'm really curious to see what this will dyno at when it's all said and done.

My guess would be 115-120 wheel.

[Jake]

Woke up yesterday morning and tightened the exhaust where it all connects at the cat. Still missing one nut (so only 3 of the 4 studs are tight) and it has an exhaust rattle as a result. I had missed one of the hangers, so I put that back on too. Some noises seem to be gone which is good.

Installed tie rods and took the car for an alignment. Was a really easy job, nothing put up a fight (*coughcough* old BMWs) and I managed to play the job of Alignment Tech pretty good, too. The shop was able to get it to 0.15° of toe, and I brought it to them with 0.25° on the left and 0.36° on the right. My past alignment experience (on my E36) involved a cockeyed steering wheel and something like 2.5°/3.3° side-to-side. So, I was happy.

Drove the car to some friends' for a BBQ yesterday afternoon in Reston, and also drove it to work this morning. Did not die in a fire. Need to fix the throttle cable still. It "stuck open" at like 2k rpm this morning, so I pulled over and fixed it - added a little slack to the cable so it shouldn't happen again, but now my pedal feels like a pile of mashed potatoes. Gotta investigate/fix tonight. No big deal.

Also, I need to re-adjust my clutch pedal. It engages too high.

[Jake]

Lots of rattles. Needs tighter bolts.

Lots of fuel leaking. Probably needs tighter clamps on fuel hoses on the manifold side of things.

[BLINGMW]

Stuck throttle and leaking fuel. What could possibly go wrong? :dunno:

Sometimes I stop and think, man, what if you gave a car like that (not to pick on your car, my cars are often like this too) to one of the unwashed masses that doesn't even know enough to get themselves out of the stuck-floormat-130MPH-down-the-highway-what-should-I-do situation? It could be an entertaining reality show at least.
Folks like us seem to have a LITTLE higher threshold for what we consider "broken" or "undriveable". Those are just extra fun challenges! Tires losing air, leaking fuel, no clutch, stuck throttle, DJ's tow vehicle with no brakes... eh, I'll fix it next week. :thumbup:

[Jake]

Stuck throttle and leaking fuel. What could possibly go wrong? :dunno:

Sometimes I stop and think, man, what if you gave a car like that (not to pick on your car, my cars are often like this too) to one of the unwashed masses that doesn't even know enough to get themselves out of the stuck-floormat-130MPH-down-the-highway-what-should-I-do situation? It could be an entertaining reality show at least.
Folks like us seem to have a LITTLE higher threshold for what we consider "broken" or "undriveable". Those are just extra fun challenges! Tires losing air, leaking fuel, no clutch, stuck throttle, DJ's tow vehicle with no brakes... eh, I'll fix it next week. :thumbup:

Oh, they would die. Or crash. And then die.

In fairness, I noticed the puddle on the driveway and took the ST to work. It's supposed to rain later today anyway

[Jake]

Problem (hopefully) solved. Took the top half of the intake manifold off (thanks Mazda, the two-piece design makes life easy!) and the one fuel line wasn't attached properly to the hard line. It hadn't been slipped over the little "bump" in the hard line, so the clamp was doing its damndest to seal, but it wasn't tight enough. So, I fixed that.

I hope I put the clamp on the right side of the bump. Guess we'll find out.

[Kaan]

:fire:
Try to avoid that

[Jake]

Alright, this thing might actually touch Summit Main this weekend if I keep up the work.

• Exhaust has been tightened for good.
• Fuel line leakage has been fixed.
• Vacuum leaks have been found and fixed, she idles smooth again. Cold idle is ~1k rpm so warm idle should be 750 or so.

I was having this bizarre rattle/knock/something from the front end at idle, that sounded like a loose motor mount. After checking the motor mounts, DJ suggested it might be that everything was tight, but not perfectly 'square' to the subframe and PPF, thus the rattle. So last night, I jacked it up and loosened the two motor mount nuts and three trans-to-PPF bolts, then started the car and ran it for 30 seconds or so. Went back underneath and tightened everything to proper torque specs.

On jack stands, it's quiet. Not sure if putting it on the ground will make any issues prevalent, but we'll see. I'm wondering if things were too loose, too tight, or tight-but-not-square.

Tonight I need to change a belt (awful squeal on startup, eek) and install my 6-points. Drill bit has been purchased, I'm not thrilled to drill through my floor but I really need the harnesses in there before Hyperfest. So... away we go.