Andrew's '93 NA6 - KL V6 swap

[Beelzeboss]

balls

Pretty much sums it up.

I've taken the heads off and the gasket was definitely leaking oil from the return passages out the side of the block/head boundary on the LHS head.

Does anyone have any tips for cleaning the head/block surfaces for the new gaskets? I finish uni at 12 so I should have time to get the engine back together tonight, provided all goes well (which it never does)

[zossy1]

You need these:

http://reviews.thetoolwarehouse.net/pro ... 50-Pk.html

Not sure where you buy them in Australia - I usually buy them on eBay USA and have them shipped out but I know you can get them here somewhere...

[NitroDann]

Use a razor blade and/or a sanding block.

Dann

[hks_kansei]

Depending on the abrasiveness of those, wouldn't there be a risk of sanding a bit much away and causing the gasket surface to be uneven (therefore making it more likely to leak in future)

I'm pretty sure most mechanics just use a razor blade.


Any remaining goo I imagine a bit of metho/turps on a rag would remove

[zossy1]

Those abrasive discs I linked come in two kinds - brown (very abrasive - for doing cast iron blocks, etc) and blue (less abrasive - for doing alloy castings like cylinder heads).

Unless you are completely ham-fisted, you can't wear any facing material away with these. If you have ever seen one you will understand why - they are made of nylon-type material, kind of like a scotch brite pad. In fact, I would argue that using a razor blade is more risky. Especially when working with alloys, it is absolutely possible to gouge the surface with the blade if you attack it too aggressively.

Add to this, shaving a cylinder head with a razor blade, and doing it properly, can take a LONG time and a lot of effort. I have done a nasty, dirty head with one of those discs, and had it looking like new, in less than 5 minutes.

[RedMX]

Found this image, dunno if its much use........ but its pretty to look at.
Dunno how hard it would be to do a plug change

[mitch_f1]

Mann, ITB's on a KL would sound THE SEX!!

[Beelzeboss]

Found this image, dunno if its much use........ but its pretty to look at.
Dunno how hard it would be to do a plug change

That looks like an awesome setup, it even looks like it would fit under the bonnet something to consider upgrading down the track. I really wanted a supercharger but I don't want to have to upgrade the gearbox so I think it will stay N/A. Once it's registered I'm thinking of getting a set of upgraded cams, though I feel the first thing I should upgrade is the exhaust manifold which is annoying because there really is no space at all for a decent set of extractors.

I was up until 1:30 getting the engine back together, it looks like the car will drive tomorrow All that's left is to tweak the tune a bit so it runs properly. I'm going to try and get a permit to drive to a few places so I can tune it on the road.

Mann, ITB's on a KL would sound THE SEX!!

It sure would, I love that video of the blue MX-5 with the KL on ITB's, such a great sound.

[PaulF]

I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

[RedMX]

I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

I don't think it would be too hard to box them up as they sit now. No real different to the Mazdaspeed B6 ITB cover/intake except having the pods in there too.

[ampz]

Not sure if it's already been covered here, but the Vitara V6 share the same block, granted the engines are chain drive vs belt but at a guess maybe the intake manifolds fit the port spacings?

There's a place called suzifour spares in St Marys, might be worth taking your spare manifold to check it out.
I've seriously been looking at a similar mod to my NA6, but using the Suzuki version of the KL, it already has the FR orientation and COP standard. The weakness of the timing chain tensioners is what is putting me off the conversion.

[bruce]

I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

He would be thinking SIX filters? Oh, it's a six cylinder...!

[Beelzeboss]

Thanks for the comments everyone

I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

they'd have a field day, the way they go on about the dangers of pod filters.

Not sure if it's already been covered here, but the Vitara V6 share the same block, granted the engines are chain drive vs belt but at a guess maybe the intake manifolds fit the port spacings?

There's a place called suzifour spares in St Marys, might be worth taking your spare manifold to check it out.
I've seriously been looking at a similar mod to my NA6, but using the Suzuki version of the KL, it already has the FR orientation and COP standard. The weakness of the timing chain tensioners is what is putting me off the conversion.

Thanks ampz, I don't have a spare manifold though, both the ones I have are in pieces. I'm fairly sure I'll supercharge it at some point down the road so I don't think I need yet another N/A manifold.

It's been a while since my last update and a lot has happened. The car isn't registered yet because I've had an issue with the remote oil filter. The line popped off from the pressure. Luckily I shut the engine off about half a second after it happened so I'm confident there's been no damage but I'm remaking the entire system to take a cheap/large Z9 filter (Commodore V8, Falcon, etc.) and using braided AN-10 lines. This is one area where I don't want to have a failure so I'm going all out to ensure reliability. I'm also going to put in an RX-7 oil cooler across the front of the car.
I have a 1 week break from uni in about 3 weeks so I'm hoping to get it finished then, but it very well may take until November before it's registered. 2nd semester 3rd year mechanical engineering is really time consuming

[Beelzeboss]

I've been pretty busy with uni lately but I have managed to do a bit on the new remote filter setup. I'm using a Z9 filter which is massive compared to the original, it's used on Holden 5.0's and a few other big engines. They're cheaper than standard MX-5 filters, too.





^ Ignore that drawing, I've changed it from an NPT thread to an external -10AN thread to make the whole thing shorter and eliminate a point where it could leak.









I've done a bit more but my camera battery went flat. Yesterday all the braided stainless hoses and AN fittings arrived from Summit so with any luck I'll have it plumbed in and running by the end of this weekend.

I also did a bit of wiring for the tacho. It needs a pullup resistor for the adaptronic so instead of wiring it in externally I made a simple resistor with crimped terminals which bolts on to the back of the cluster. It works perfectly so far and is easily removeable.



By the end of today I hope to have the filter side of the oil filter relocation kit finished, tomorrow I'll work on the engine side which should be much less complicated.
I decided to make my own because I wanted to use 3/4" NPT threads because I already have that tap. It's also the size I'll use for the -12 dry sump scavenge line.

Also I've booked in to see an engineer in a few weeks.

[Beelzeboss]

Well I didn't get it quite finished tonight but it's close. I just have to weld on a piece to the central shaft and drill a few holes to secure it to the outside housing.







As always comments, questions and criticism welcome.