My standard and slow build thread...

[Jeff23spl]

It took me a bit long to get ready to do it.

The car had the first issue in 2014 and the compression on #3 was about 20-25psi lower than average. My mother also started fighting a lung cancer. We are close in the family so i put this aside and continued using it. It was my first DD but i switched using my beater a little more.

My mother finally lost it, last fall. My father started having too much spare time to tell just this so he is helping me with the rebuild.

I ordered the parts during boxing day sales. With the low value of our can$ against us $ i limited my list to this:

[Jeff23spl]

I checked the parts weight:
Pistons where about 0.5g average. The rods where like shown on the box. I don't have the hanger for individually weight the rods ends but the 2 heavier ones was also the ones with the heavier big ends. So i removed 1 gram of the 2 heavier big end. I polished the side and belt sanded just a little bit the cap bolts to remove that small amount of material. I did it slowly to avoid overheating them and I didn't messed with the rod integrity. I will match the heavier piston with the lighter small ends insted of sanding anywhere else. It will end up being within 0.5g average, it should be enough...

[Jeff23spl]

A lot of parts on the floor:

[Jeff23spl]

I didn't had any real problems taking it out by the bottom. Just the A/C bolt were a bit jammed.
The clutch is still in good shape.

[Jeff23spl]

Clutch looks thin but it is build this way.

[Jeff23spl]

The A/C clutch was making some noise...i don't know why...

When it is too cold, i take time to paint some parts too:

[Jeff23spl]

more pics and the damages. #3 got the broken ringland problem and we can see the spot on the bearing that is probably when the knock even happenned. I have it on all rods but only #3 piston seem craked.

[Jeff23spl]

The bloc have compression leaks but it looks like a fresh bore could get rid of them. The machinist will tell me.

#2 or #3 :


Only cylinder #4 was looking almost new.

[Jeff23spl]

I made a tool to hold the crank pulley while removing the crank bolt. Not shinny but works fine!

[Jeff23spl]

I marked the crank and the timing gear while it was at TDC, Then put back the front cover to align the pulley with the M6 bolt and marked the pulley damper to get all them keyed. Here is picture of my marks:

(On the crank roll, there is just paint mark...)

[Jeff23spl]

i have few question if someone read it :

Is the ring around the exaust port there for good reasons or i can port to match the gasket and exaust manifold to make it flow more? It is very strange because it seam to have been especially made this way...? but it also look very restrictive....? First pic is with the gasket removed, we can see the mark of gasket size...

[Jeff23spl]

is that marks normal on the retainer? it seem to comes from the tapet casting ?

[xfrank98x]

Interresting,i'll follow this !!!

[rodger14s]

Looks like a really good write up, keep it coming!


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[Jeff23spl]

it is moving slow.
I got the bloc bored to 88mm. I cleaned the head and send it to be slightly ported and planned 0.008'' to rise compression up to 9.7:1 and have a fresh surface.

I cleaned and painted few parts. The crank got keyed too and it is out to be balanced tomorrow.

[Jeff23spl]

bloc and oil pan paint

[Jeff23spl]

timing cover
Keep in ming the car has run 8 winters in north east of Canada so everything was rusty aroud there. I had to brush it before applying any paint.

[Jeff23spl]

the bored bloc

[Jeff23spl]

My poor's man flow bench Leaf blower flowing thru a Mazda 2.0l MAF and reading 0-5V
I was just checking about how much oem part was unbalance.

I measured a 10% lower flow from the #4 intake path and obviously it was the one with less wear.

[Jeff23spl]

At the moment i'm looking to find how much play it is allowed for the valve guide. Once cleaned, it seem a bit loose..not sure if it need to be dry or covered with an oil film to be checked/measured...

[Jeff23spl]

valves where good, i just did a little lapping with paste

[Jeff23spl]

head got ported a little bit

[Jeff23spl]

Made the ring gap to the spec of 15 to 30 psi so 0.024''

[Jeff23spl]

checked the new bearing and rod clearance to make sure there is no error even if the crank is perfect.

[Jeff23spl]

crank got balanced to 1/3of a gram not a big deal if you look at what he did. The larger hole was factory and we added the smaller ones.

Damper got the same.

My collegue wasn't able to put the FW on the machine so i will keep it like ACT made it...

[sheston]

Looks like a fun build. Lots of details

Can't wait to see some numbers

Good luck

[Jeff23spl]

My low cost dual PCV plate. I first tryied it as a test on a spare plate but i was surprise how solid is the plastic. I filtered 3/4'' npt and screwed the nozzle in with locktite. Then added a layer of epoxy to add a little strenght. IT is not as shinny as the aluminium model but it will do the work. Anyway once in the car with everything installed, it is hard to see it...

[Jeff23spl]

some other pictures

[Jeff23spl]

What it will look like

[sh4d0w]

I'm powder coating my subbie engine bay black and gold right now basically I'll be doing the mazda after... Looks good man loving the colors.

[Jeff23spl]

Top plate brace and caliper are also gold. I may look for blacl silicone coupler because the red ones i have make a bit too much colors. I would also need a gold oil cap but i won't paint the Msspeed one...

Unfortunately, the car will probably run during winter so it may not remain clean for long...

[impossible]

Looks great man, is it in the car running yet?

[Jeff23spl]

Thanks
Just started last sunday, run perfectly fine. A bit rought before getting up to operating temperature but overall quieter than my used stock bloc lol

Not sure if it was the accessory bearing replaced or the timing chain ...maybe both but it is a lot more quieter than before the rebuild. I was afraid forged piston could make a slapping noise at cold but it don't.
I will also have to do a new maff cal because everything seem off in neutral.

Just 1 thing, my radiator fan do not seem to want to run. It was a used one and maybe it isn't working anymore or i have a connector not installed. Temperature gage works and obd coolant temp also...
I plan to drive it soon.

[802MS3]

where in QC are you?

[Jeff23spl]

Originally Posted by 802MS3 where in QC are you?

near Qc city ...but why ?

[Gribbs1469]

subscribed

[Jeff23spl]

Body isn't cleaned but the engine is in

[802MS3]

Originally Posted by Jeff23spl near Qc city ...but why ?

Just curious, I'm close to the CA border, hoping to make it to a couple meets up there this summer.

[Jeff23spl]

Oh i see. I even drive to Burlington airport once to catch a cheaqper flight from there but it was about 4hrs drive. Quebec is more to the east side and a little bit more north than Montreal. Montreal is closer...

I know that some of us will do a Mazda trip to M Washington on august 13th. Not sure how close they will pass from Burlington but it is almost on their way...
I dont think to be part of the group but it is not confirmed yet.
Some goes to Napierville racetrack often.
There should be a an annual mustang dyno day at the end of summer around Montreal.

You can check meet events from our French forum and i can help if you don't understand french (Mazda3Quebec)

[rotormike]

Im really digging that leaf blower idea