Slotege KLZE Swap Thread Take #2

Since the old thread got deleted,

Over the next couple weeks I will be trying to re-create the swap thread I had before. It's going to be a lot of work since the last one was made over 10months of research and buying parts. I think for reference purposes having this thread will help future swappers or for reference for those already swapped or interested in what a protege can become.


Stay Tuned.......

Parts List:
Engine - KLZE Straight Neck - $880
Transmission - Mazda 626/MX6 5-spd - $300
Differential - Team MFactory Helical LSD - $670
Clutch - Southbend DXD Rally Series Stage 1 - $180
Flywheel - Shaved MX6 Flywheel ~12lbs - $120
Harness - 1994 MX6 Engine Harness - $100
ECU - KL36 - $120
Distributor - 1994 MX6/626 Distributor - $65
VAF - JE50 from a 1992-94 MX3 - $25
Headers - MX6/626/Probe GT Pacesetter Headers - $220
Intake - MX6/626 SRI w/ Protege 1.8/2.0lCAI extension - $45
Radiator - MX6/626 Radiator - $40
Intermediate shaft - 1994 MX6 Shaft with modified mount bracket - $30
Axles - 2003-03.5 MSP Axles - $275
Starter - MX6/626/Probe GT Starter - $20
O2 Sensors - 1994 MX6 O2 Sensors - $140
Transmission Bracket - 01-03 Protege/P5/MSP Mount Bracket - $40
Rear Mount - Modified 1.8l Bracket and using Protege AWR rear mount - $0
Front Mount - MX6 AWR Front Mount - $60
Battery - Braille B2015 - $165
Tach Adapter - Dakota Digital Tach Adapter - $70
Clutch Slave - $30
Prosport Oil Pressure Gauge - $40
Prosport Oil Sandwich Plate - $30
Transmission Saver Bracket - $35
Basic Maintenance - Timing Belt Kit w/ Tensioner, New Gaskets, New Seals, Thermostat, and Hoses.
Fluids - 4.5qts Oil, 3.2qts 75w-90 Gear Oil, 2 Gallons Coolant, 2qts of PS Fluid, Some DOT 3/4 Brake Fluid.
Misc - Hose for PS suction hose, hoses for heater core, vacuum, and fuel, Assorted bolts and clamps

Totals:

Reserved #1


Photos of Parts:
Engine:


Transmission:


Clutch:


VAF:


Radiator:


Tach Adapter:


Oil Filter Sandwich Plate:


New Clutch Slave:


Speedometer Ring for LSD:


Transmission Saver Bracket:


Team MFactory Helical LSD:


Transmission Bracket:


Photos of Prep. Work
Intake Manifold and Valve covers off for initial inspection:

Old Crap:


First Night of Work:


Valve Covers Painted:


Intake Manifold and TB Painted:


Transmission Painted:


Engine Stand Finally Arrived:


Cleaned Block and Heads Ready for Paint:


Inspecting bottom end:


Fuel Rails Painted:


New Vacuum Plumbing:


Valve Covers Back On:


Painted Heads and Block:


Intake Manifold, Fuel Rails, and TB Back On:


New Waterpump and Timing Components:


Modifications to the Intermediate Shaft:


Modified 1.8l Trans. Bracket:


Team Mfactory LSD Installed in Transmission:

Reserved #2

Photos Before, During, After:

Before - 1.8l FP-DE w/ Cone filter in place of airbox


During - FP-DE Coming out


FP is Out


Engine Bay is Empty


Cleaned, New Harness Ran, Exhaust is Shortened Ready for the KL


KL is in place and bolted up


PS Line Relocated


1.8l Passenger Mount Works


Completed and Running


After - CAI, AFPR, Wire Cleanup, Braile Battery Replaces the Odyssey, Etc...








Cruise Control Added


Video of Startup and Walkaround:

Reserved #3

Mechanical Information:
Motor: JDM KLZE Straight Neck
Transmission: 1998 626 V6 Transmission
Mounts: Driver Side; Protege, Rear; Protege w/ modified bracket, Front; MX6, Passenger Side; 1.8 Protege
Exhaust: MX6/626/PGT Pacesetter Headers, Shortened Protege Mid-Pipe, MSP Axle Back
Radiator: MX6 w/ modified lower mounts to sit in the protege radiator support, MX6 Hoses
Axles: 03 MSP Axles, 1994 MX6 intermediate shaft w/ modified bracket to bolt to the KLZE
Power Steering: New Suction hose cut to length, Protege P/S Reservoir, Protege Pressure Line, and Protege cooler lines and cooler.
Intake: Modified KL31 Throttle body w/ Protege throttle cable mount to clear the master cylinder, MX6 ebay short ram, Protege Lower section CAI w/ AEM DryFlo Air Filter
Battery: Modified Protege battery tray, Braille B2015 15lbs Slim Battery, Universal Battery Tie down rods and 2nd Gen Protege Tie down cut to length
Heater Hoses: Cut to length coolant hose of the correct size
Fuel Lines: 3/8 Fuel lines cut to length
Brake Booster Hose: 3/8 Hose cut to length and a check valve inserted to allow vacuum only
Shift Linkage: Protege Shift Linkage, however, this changes the angle of the shifter int he car slightly. Others have used PGT linkage to get the correct angle back.


Electrical Information:

1994 MX6/626 ECU Pin Locations / Wire Colors Used
22-Pin Connector
Pin 1: Constant 12v Power - BL/R
Pin 2: Start Signal Input from Ignition Switch - BK/R
Pin 11: Ground - BK
Pin 12: PCM Power - R/BK
Pin 20: Neutral Safety Input - LG/BK
26-Pin Connector
Pin 1: Ground - BK
Pin 2: Ground - BK/R
Pin 14: Ground - BK
Pin 15: Ground - BK/BL

Protege Wiring - To get the cluster in fully functional condition, aside from the fan relay, and fuel pump relay the motor should be safe to run without this.
Ground Fuel Pump Relay at ECU
Wire tach adapter to cluster and tach signal wire on distributor
Use Protege Coolant temp sensor in the second coolant temp sensor location (KLZE only), extend Protege coolant temp wires to sensor.
Use protege reverse light switch and wires.
Use a 98+ 626 Speed sensor and Protege harness to run the speedometer on the cluster.
Use an aftermarket thermostatic fan relay

Maintenance Information:
Oil: 5w30
Qty: 4.5qts
Oil Filter: MX6/626 filter
Gear Oil: 75w90
Qty: 2.9qts
Spark Plugs: NGK BKR6E-11
Distributor Cap and Rotor: MX6/626/Probe
Axles: MX6/626/Probe Intermediate Shaft, 01-03 2.0l Protege Axles

Subbin...any particular reason as to why the old one got deleted??

sick

IukekiniProtege said:

http://www.mazdas247.com/forum/showthread.php?123813365-Missing-Proteg%E9-Forum-Threads&highlight=

Click to expand...

Oooooo damn, that kinda sucks.

yeah I personally lost my swap thread with a whole crap load of info that i doubt I will ever remember it all to put here, and lost my build thread. Oh well... time to rebuild the threads the best I can

^Wow, man. Sorry to hear that!

It was great meeting you! Not many days pass that Evan and I don't talk about your car at work!

Here it is in Ohio, embarked on an epic road trip!

Sick car, I like how clean the swap looks... I am thinking of actually swapping a FP 1.8 for my ZM 1.6 so I can boost it. There is not a lot of options for upgrading the 1.6 and I already have most of the bolt on parts... The KL swap looks like a lot of fun and I bet the car actually moves with that under the hood.

Why waste your time with the FP? It is decently quicker than the 1.6 My best time with the 1.6 was 17.95 and the 1.8 was 16.8. But the thing still uses an absolutely garbage transmission. The G-series guys b**** about our transmissions, but the F-series is even worse. And with a g-series you have gear options, more LSD options and different ratio options. for the amount of time, effort, and money you are going to spend on a FP or even a FS you could swap in a KL and be at the same power to the wheels as a boosted FS with a few mods. If you do a KLDE then your slightly less power than the ZE, but can boost it more. The ZE is great N/A, but responds well to light boost. Check out probetalk. Quite a few 300whp PGT with KLDEs and KLZEs running 10-14psi on different sized turbos. Those numbers are only reached with fully built FS motors whih will double the cost of your plans.

I hit 52k Miles on the swap earlier this week. Still going strong.

Just finished the wiring information and added some maintenance information to the beginning of this thread.

Sub, again. (bowdown)

subbed

Totally subbed!

So when you said you modified the Intermediate Shaft, what exactly did you do? Would an FP or FS Intermediate Shaft not fit the KL Transmission?

fs will fit in trans, but the mounting bracket wont work, and i modified a 94 mx6 shaft mount bracket to bolt to a ze block

Awesome! Do you have any pics of that? I'd be interested in seeing them...

this is more tempting everytime i look in here, ihone and lewis thread

(headbang)

Unreal amount of documentation and prep work went into this. Kudos. I wish I had spent that amount of prep time before doing mine. I now have to take a weekend to pull it out again and clean up everything. I have a slow leak in/around the timing cover area I haven't pinpointed yet.

One of my biggest problems was fitting the straight neck, I ended up just settling for a curved neck for now. Any chance you can give some detailed info how you fit the TB from the straight with the brake booster location? I wasn't able to clear it, especially not with my outlaw spacers.