93 BB base FD build-up

[Chadwick]

First and second post update with a bunch more pictures.

We started the car today and it is purring like a kitten but we did have a little drama getting there.

Yesterday we buttoned everything up and started to fill her with fluids. When she got about ¾ full of water a small leak was apparent. It looked to be coming from the coolant supply hose to the turbo. We took off the hose, inspected it and the fitting then re-clamped it. To our surprise it was leaking even worse. That is when we noticed the water was coming out of the fitting that is pressed into the water pump housing, not the hose. We had to tear everything back off the front of the motor and replace the housing. While Brian, Andrew and I worked on getting everything back together, Mike polished the crap out of my Greddy Elbow and intercooler .

With the water leak fixed Brian wired up the FJO injector driver and I wired up the Jacobs and we were ready to turn the key. Brian cranked her for about 6 seconds and she started to fire but he had already committed to releasing the key. He hit it again and she fired on the second crank. Right from the start she idled super smooth and only kicked out smoke for around 5 minutes. Andrew and I adjusted the fuel pressure and we let her get up to temp watching for any leaks the whole time. That is when we noticed a mist of what we thought was water coming from somewhere on the front of the engine. It was being slung by the belts and making a mist so it was really hard to tell where it was coming from. I had Brian kill the engine.

With the engine off it became obvious that it was not water but oil that was being slung and we could see right where it was coming from, the front bolt on the eccentric shaft. Brian and Andrew pulled the piping and intercooler and we removed the bolt to find the crush washer had shifted when it was torque down. I promptly threw the crush washer in the trash. Brian applied a layer of RTV to the bolt and we reinstalled it.

We installed all the plumping back and fired her up for the second time. Maybe 2 or 3 cranks and she fired right up, this time with no leaks. We let her run for about 30 minutes and check all the pressures and temps. She is pulling 16-18 of vacuum at idle which is great for having all new seals and running for less than an hour total.

We all seem to think she has a deeper tone then before with a little stronger pop to the exhaust pulses.

Hopefully we can get everything else button down this week and get her on the dyno next weekend.

Stay tuned,

Dan

[afterburn27]

Awesome build! I am very jealous...

I just wanted to make one comment about this:

Originally Posted by Chadwick

With the engine off it became obvious that it was not water but oil that was being slung and we could see right where it was coming from, the front bolt on the eccentric shaft. Brian and Andrew pulled the piping and intercooler and we removed the bolt to find the crush washer had shifted when it was torque down. I promptly threw the crush washer in the trash. Brian applied a layer of RTV to the bolt and we reinstalled it.

You probably already know this, but when you loosen or remove that front eccentric shaft bolt with the engine in the car it can cause the thrust bearing to drop out of place. After a while the bearing, spacer, and thrust plate will wear down and possibly get chewed up and spit into the oil pan. This can also cause vibration and the bolt might end up removing itself after the bearing is completely destroyed. When that happens you are in a world of trouble. Don't ask me how I know...

Just something to think about...

http://www.mazdatrix.com/faq/pulley.htm

[sbrian2]

Originally Posted by afterburn27

You probably already know this, but when you loosen or remove that front eccentric shaft bolt with the engine in the car it can cause the thrust bearing to drop out of place. After a while the bearing, spacer, and thrust plate will wear down and possibly get chewed up and spit into the oil pan. This can also cause vibration and the bolt might end up removing itself after the bearing is completely destroyed. When that happens you are in a world of trouble. Don't ask me how I know...

Just something to think about...

http://www.mazdatrix.com/faq/pulley.htm

We were aware of the possible problems and Andrew stayed in the car with his feet on the clutch and brake from the time just before the bolt was loosened until it was re-torqued. I feel confident that the trust bearings remained in place.

[afterburn27]

Originally Posted by sbrian2

We were aware of the possible problems and Andrew stayed in the car with his feet on the clutch and brake from the time just before the bold was loosened until it was re-torqued. I feel confident that the trust bearings remained in place.

It was my understanding that because the FD has a pull-type clutch you cannot use the "foot on the clutch" method when replacing the front eccentric shaft bolt. Pushing the clutch in pulls the flywheel away from the engine... the opposite of what you really need.

Chances are that the engine is fine and the thrust bearing stayed in place... but it isn't pretty when that bearing fails completely. You can probably just check the end play to verify that everything is A-OK.


*edit* Here's what happens for anyone who is curious:

http://filebox.vt.edu/users/mattmck/rx7/oilstreak.jpg
http://www.carclubvt.com/photopost/u...9/DSCN0324.jpg
http://www.carclubvt.com/photopost/u...9/DSCN0335.jpg

After that bearing dropped into the pan there was enough endplay to allow the eccentric shaft to repeatedly smash into the trans input shaft and "mushroom" the splines out which trapped the clutch disk. Sitting in the engine bay for hours with a needle file was "fun". LOL

[sbrian2]

Originally Posted by afterburn27

It was my understanding that because the FD has a pull-type clutch you cannot use the "foot on the clutch" method when replacing the front eccentric shaft bolt. Pushing the clutch in pulls the flywheel away from the engine... the opposite of what you really need.

You may be right. Dan was instructing Andrew on what to do and I was removing and reinstalling the bolt, so what went on it the car is a mystery to me. Maybe Dan will chime back in.

[Chadwick]

I had Andrew put the car in gear and his foot on the brake. I held the front hub the whole time while Brian removed and installed the eccentric shaft bolt. If there was any movement in the shaft I would of felt it. A quick check of the shaft play confirmed everything was A-OK.

Dan

[afterburn27]

Originally Posted by Chadwick

I had Andrew put the car in gear and his foot on the brake. I held the front hub the whole time while Brian removed and installed the eccentric shaft bolt. If there was any movement in the shaft I would of felt it. A quick check of the shaft play confirmed everything was A-OK.

Dan

Good deal!