Slotege KLZE Swap Thread

[IukekiniProtege]

Well, here's the plan. It has been done before I know so I'm not the first, however I would like to share everything going on so far just due to the fact that it is barely talked about here on Mazdas247.com. So, I am including my parts list, prices, pics, trouble i run into, work arounds, and other helpful info. So look at this as a Write-Up How To/Build Progress Thread.

Goal:
Swap a Straight Neck KLZE 2.5L V6 into my 2000 Mazda Protege LX to replace my dieing 1.6L ZMDE.

Part List:
Engine - KL-ZE Straight Neck - Bought - $880 Shipped
Transmission - Used MX-6 Transmission - Bought - $150 Picked Up
LSD - Used Mazdaspeed Protege LSD - Bought - $230 Shipped
Speedo Drive Gear - Mazda OEM New - Bought - $14 Shipped
Clutch - South Bend Rally Series Stage 1 - Bought -$196 Shipped
Flywheel - Stock OEM Mx-3 GS 1.8l v6
KLDE/ZE Gasket Kit - Bought - $55 Shipped
1994 KLDE 8-Bolt Crankshaft Spacer - $20shipped
Power Steering Reservoir - Bought - $24 Shipped
ECU - KL31
Wiring Harness - MX6 LS 93/94 OBDI - Bought - $128shipped
Distributor - MX6 LS 93/94 OBDI - Bought - $85 shipped
Universal Tach Interface - Dakota Digital SGI-8 - Bought - $75 Shipped
Passenger Side Mount - 2.0l Protege OEM or SLS Mount
VAF - Mazda JE50 - Bought - $50 shipped
VAF - Mazda KL03 - Bought - $35 Shipped
Headers - PaceSetter Normal Coated wrapped with Header Wrap
Intake - Aftermarket Cold Air from MX6
Battery - Slim Odyssey PC680 for fitment issues - Bought - $129 Shipped
Radiator - OEM from a 2g MX-6 LS - Bought - $60 Picked Up
Intermediate Shaft 2g MX-6 LS - Bought - $30 Picked up
Starter - 2g MX-6 LS - Bought - $40 Picked up
Power Steering Reservoir - OEM 2g MX6 LS - Bought - $19 Shipped
Axles - Both side 2.0l Protege axles
Timing Belt Kit w/ Early Style Water Pump
O2 Sensors - OEM MX6 Upstream sensors
Gaskets - Complete Engine gasket set - Bought - $50 Shipped
More small stuff....

Notes:
1. When buying a valve cover, head gasket, intake manifold, and exhaust manifold set; make sure that the set includes the intake manifold gaskets for a ZE as well. There is a big difference between ZE and DE manifolds. Exhaust manifolds should be the same.

Total:
$2,249.63 to date more to come

Pics:
Radiator - 2G MX6 LS 2.5L V6


VAF - JE50


Universal Tach Interface - Dakota Digital SGI-8


Straight Neck KLZE from an Automatic - Bought from JDMEngineZone.com
Arrived







Head Stamping - KL31 1A1 and KL31 101



Cam Stamping - KL31


Above


Random


Gaskets and junk


Zip-loc + marker = Saved time




result after Day 1


More & Progress Parts 7-23-2009:
Prosport Oil Sandwich Plate


Odyssey PC680 Battery


New Slave cylinder


Painted the valve covers-its bronzey silver, but the camera picks up mainly the silver, very cool color though


Intake Manifold Before:


Throttle Body Before:


Intake Manifold and Throttle Body After:


Prosport Electrical Oil Pressure Gauge and ForceFed Gauge Pod:


Transmission Before/During De-greasing:


Transmission After, not perfect but definitely better:


Clutch, Speed Gear for Transmission after differential install, wheel well plastic to replace my torn one:


DXD Southbend Rally Series Stage 1 Clutch:


Mazda KL02 VAF from US 2.5 in case I need to go with a US Ecu for a bit or decide to go with a chipped us ecu:


Mazda KF34 Distributor from US 1994 MX-6 LS:


Stock Fuel Rails and Injectors, painted a Mazda6 red with a lot fo metallic in it, I will try and get a better pic showing the metallic:


Quick Mock up of the current progress:


7/29/2009; Finally got my engine stand, Oil pan off and everything inspected; looks all good:


Block all degreased, and almost ready for paint:


Much neater now that the pallett is gone and everything is organized:


Bonus Pics: DSM Wreckage in my friends garage where we are working on the KLZE; 7-bolt DSM + crank walk + 27psi of boost for three weeks on stock tune = This:




Worked on the vacuum plumbing

Old tubing that was hard as a rock:


New tubing all in place:


New fuel line on the end of the rails, and another view of the completed intake manifold:


Painted the heads and block:
Block looks weird in the pic its a much darker color in person, flouresent lights trick ya along with flash:


Used MSP Limited Slip Differential



more to come....

[IukekiniProtege]

Here is the result of this past weekend. Project is temporarily put on hold.












September 15, 2009: New Slotege - Slotege_1.8

9/11/2009:
Day after I got it:







Today - 9/15/2009:




Clear coat issues on trunk:


Old one repainted by my friend, ready to install:


Interior:

[IukekiniProtege]

Reserved 2

[IukekiniProtege]

Reserved 3

[xJAZx]

i cant wait

[TWISFM]

sub

[IukekiniProtege]

im plannign 3-4 weeks for everything to be ordered and arrived and ready to go in, then we are dedicating a Fri, sat, sun to the swap.

[red99pro]

wish it was me...do get scooby's turbo also........plz

[Wagonbacker9]

sub

[Dparks7]

sub

[el_Don]

Subbin'

[fishdonotbounce]

This will be another KL swap to envy. Congrats on the purchases man. The bump in power will be enormous.

[IukekiniProtege]

Parts list mostly added, left out stuff liek clamps, hoses, and other stuff, if you curious to see the spreadsheet I can post a link to it.

[xDJ DUBx]

yummy

[Protege03ak46]

subin