FSZE Protege5 Track Build

323

(u_u) ...zZzZzzz
Moderator
That's dope man. I don't think I've ever seen anyone go all out and utilize the FSZE harness and ECU. Excited to see how that turns out.
 
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2015 Mazda 6
I received a better graph of the dyno comparisons of the FSZE with the MP3 Ecu and ZE with the ZE ECU. The numbers are different by 2hp/2tq. But what’s really different is the power band shown in the graphs .
I am going to make an effort to install the Ze manifold and dyno it again to see what it does to the powerband.
 

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2015 Mazda 6
I had the honor of being asked to help the Jzilla Trackday team instruct this event. I dont consider myself a pro, and I treat every event as a learning experience. But I was really humbled to be asked to instruct new students to the group.

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I had 2 students, one with a STi, and another in a Audi S5. I felt bad, that these guys had to follow me around the track in my ole P5. But the key to any trackday is to have fun and be safe. So its part of the process.

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On the second day, only one of my students was able to make it. So it let me focus more time with one student. My student had done a few track days, and had plenty of experience on track, so at this point we were just going over things to be sure he was ready for his ride-along for the solo group. Being my first time instructing it was a great experience. I am not a professional by any means, but I am thankful for the team at Jzilla for trusting me with the task of doing so.


My personal track day was pretty good, no real complaints except for the weather. And with the big hole in the sunroof it made it far more complicated. But I took advantage of the wet conditions and did a few sessions in the rain. At first the idea of the challenge was fun... but Road Atlanta tends to create puddles in the worst areas during hard rains. And with the R888Rs it was sketchy at times. But this video above was one of my most fun runs in the rain. Being wet on track, it gave me the advantage a little and helped me keep up with some of the quicker cars in the run group.

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I ended up leaving during the last session to get ahead of another round of storms. But I managed to run right into it on my way home. Besides the foggy windows, it wasnt too bad. And if I kept a decent speed I would not get wet.

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I made a stop for some food....and the weather had made a full turn to sunny skies...

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A good friend of mine, sent me a craigslist ad for a Free Protege 5. I honestly was not looking for one, but it was semi- complete and had a engine and transmission in it.

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Upon further inspection I found out that the car was owned by Paul of Mazmart for many many years and had spun a bearing and had been sitting at Mazmart for years before someone got it for parts. And the guy had gotten all he wanted off it. So it was my turn....

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The main thing that I wanted was the transmission out of it as a spare for future build / upgrade. The car was full of random protege parts, but at this point I had plenty of spare parts. So besides the engine harness , engine , trans most of it remained. And it was sent off to the scrap yard...

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I also took the time and upgraded the passenger side engine mount to the newer Hydra Motorsports Billet Engine Mount .

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The AWR Engine Mount I originally had was absolutely fine, and worked well. But I got it used, when I first put the car together and it was time to get something fresh in there.

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The engine mount fit like a glove, but in order for it to be installed , you will need to cut and or remove the top timing belt cover. The difference was crazy, the engine went from slight movement to no movement.

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Next stop was Atlanta Motorosports park...
 

njaremka

Wiggity-Wack-O-Tack
Contributor
:
2011 MX5 GT
I received a better graph of the dyno comparisons of the FSZE with the MP3 Ecu and ZE with the ZE ECU. The numbers are different by 2hp/2tq. But what’s really different is the power band shown in the graphs .
I am going to make an effort to install the Ze manifold and dyno it again to see what it does to the powerband.
I find this VERY interesting. Thanks for sharing!
Isn't the FSZE ecu supposed to rev out to 7000 or 7500rpm? I can't remember...
Also, looks like the 626 manifold might be limiting your top end a bit? The FSZE manifold might be worth a bit more on the top end. Or, grab an FSDE manifold and port the crap out of it...
 

sm1ke

Work In Progress..
Moderator
Contributor
:
Canada
:
'18 CX-9 Signature
I love me a good build thread. Thanks for sharing, @JITB!
 
:
2015 Mazda 6
It was time to get back on Atlanta Motorsports Park, this was my first time there with my new seat. And I was so excited to finally be able to be secure in the seat and focus on driving. But I had been struggling all day with grip. I had initially thought it was because the track was cold earlier in the day. But as the day it never went away, and I was fighting with the car in the turns, and it just didnt have the grip it normally had. You can see how much effort it was to make the turns, and how noisy the tires were in the carousel..


After the event, I looked over the car and noticed that my tires were done, and I put the car back on the alignment rack, and my alignment had been all out of wack. In the past I tried to re-align the car before every event, but I had gotten away from it this year, and this is the results. This ended up being the last event of the year for me. As I decided not to spend the money on tires for one event. And I did want to look into changing wheel/ tires setups again next year. So back in the garage for the winter, and some updates...
 

RuskiiGuy

Boostedlife
:
2003.5 msp
Loving this dude, epic. My dream. Check out my build, I am making my car for the exact same purpose, track racing.
 
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2015 Mazda 6
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With the JDM engine installed last year, I had always been curious on what it actually makes in comparison to the US engine...


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Above, I have the dyno comparison of the US FSDE engine with bolt-ons that makes 113 hp and 102 tq . And with the JDM FSZE my car put down 132hp and 137tq on the dyno using the US engine harness and Mazda MP3 ECU.


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The real reason for going to the dyno was because I was able to source a proper JDM harness and ECU to properly run the FSZE engine in my car. The harness and ECU was from a guy in Canada that had purchased from someone else, that extended it to fit in a LHD vehicle. So I removed the US harness to get ready to install the JDM harness...


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Here is the US harness shown up top, and the japanese harness below. The car that the harness came from was a ABS car, and mine was not, so it is excessively long with things I did not need.


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In order to use the FSZE ECU I will need to remove my lightweight pulley and swap the crank sprocket to the matching JDM sprocket on the left...


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The harness was in, and I just needed to plug in everything and crank it up..


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So being that the JDM harness was a ABS car, it used the ABS unit to monitor speed with the speed sensors on each wheel. In order to get around that I needed to run a signal to the speed sensor in the trans.


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I had a spare harness to pull the proper connector from and make a harness for the speed sensor.


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I was lucky enough to be able to get in touch with a guy from Australia, that had access to the JDM wiring diagram, and combined the information with another local friend that was able to identify the proper pin to remove and install to plug the speed sensor in..


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I ran the speed sensor plug to the speed sensor on the trans...


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And magic... we have a working speedo!


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The JDM cars only run off a single o2 Sensor, so I plugged the secondary O2 sensor bung..


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I was able to get back on the dyno and compare the two numbers. So with the US MP3 Ecu the car made 132hp and 137tq, but with a dying power band, that peaks at 3500-4000 rpm and falls down to 90hp at redline...which explains how and why the car drags on the straights.

And with the proper JDM ECU , the car makes 130hp and 135tq... but the powerband is much more useful and ideal . From 3500 rpm to 5500- rpm I am making power and holding it in a decent range to redline...


Here is a video of both sessions..

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There was a final piece to the JDM puzzle that I needed to experiment with on the dyno. And that is the intake manifold, which features a resonance chamber to match the performance of the FSZE engine, which may make up for the loss of power in the higher rpms.


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The intake manifold is a oem part, so it fits like a stock manifold would. But the fuel rail is different, which will require some re routing. But its a pretty straight forward install.


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It was time to address the clutter of ABS mess stuffed in corner above. The idea was to remove the covering of the harness, and completely remove the ABS portion, since I had no use for it.


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Harness out again...


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Harness wrap removed, and the exact point of regret set in. As you can see the harness was extended previously by someone else and while they did do a good job. The cluster of red wires just makes this much more tedious.


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ABS plug , and speed sensors portion removed from the harness.


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Everything wrapped back up, and ready to go back in the car...


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I would be lying if I said everything went as planned. It absolutely did not, first of all when I attempted to install the harness back in the car. I had the lengths off on several sensors, so I had to then go back and extend a few connectors to make it sit properly. Once that was settled the engine bay was much cleaner. And the mess of wires were gone. I am wanting to get back to the dyno and see if the intake manifold changes anything power wise or makes the powerband even better. But I realized I have spent weeks on this hunt for power, and I needed to get back on track with the long list of repairs for the 2021 track season.....
 
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2015 Mazda 6
- Update with more in depth on the dyno session and everything. I have a lot to catch up on!
 
:
2x 2001 SP20 323's
Uuugh that red spaghetti monster is nasty! Good work getting everything up and running though.
Can confirm, a JDM sport20 pulls harder for longer than a FS-DE car, 100+ kph in second gear!
 

njaremka

Wiggity-Wack-O-Tack
Contributor
:
2011 MX5 GT
Sa-WEET! I wish there was more knowledge floating around like this when I had my Protege. It was all rumors and speculation about the FS-ZE engine. Glad to see you're tackling the project with success. My guess is you'll see positive gains up top with the FS-ZE manifold. I believe the 626 manifold is choking the top end with it's long skinny runners. Still, 135 hp/ft-lbs at the wheels with an MP3 ECU is strong. They were only rated for 140hp at the engine when new.