KLZE V6 Swap How-to (now with pics)

[MrWeeyums]

Here’s my attempt at a write-up for the V6 swap. Unfortunately, I won’t be able to help much with the wiring since I had my friend make the harness, but ill do my best. I’m not going to get into every single mechanical detail either because if you’re trying this you should have pretty good experience working on car already. First is the parts list.

Parts list

KLZE j-spec 2.5 V6 with curved neck intake manifold.

Aftermarket
Headers
UDP
2.5" exhaust w/ high flow cat
ACT Stage 2 clutch
Intake (Zx2 CTA)
10" pusher radiator fan

Mx3
All 4 motor mounts complete
Front to rear crossmember
A-arms
Modified wiring harness
Axles
Flywheel
VAF
ECU

Probe
Distributor
Alternator

Mx6
Transmission
Clutch slave cylinder + first section of hard line.

2nd gen Escort
Return fuel setup
Radiator overflow jug
Throttle cable

82 Chevy Chevette
HEI module

Most of these should be available at a junkyard, which is the way to go to keep the cost down. The engine came from an importer and the aftermarket parts were mostly ebay. Most parts can be found at a local auto parts store if they’re not in the junkyard.

1st step, assembling the engine.

You’ll want to put together as much as possible of the engine outside the car to make things much easier. It should squeeze in with all the accessories on it. Save the exhaust manifolds for after it’s in the car. Swap the alternator and distributor for American versions so they’ll work with the harness. It’s a good idea to replace the water pump, timing belt, and any gaskets that look iffy. The timing belt isn’t essential, however, since this is a non-interference engine.

http://kctuners.com/members/inis/mrweeyums/Picture%20008.jpg
http://kctuners.com/members/inis/mrweeyums/Picture%20009.jpg

2nd step, stripping the engine bay.

Pull
The engine/transmission
All the mounts
A-arms
Wiring harness
Lower front to rear crossmember
The front bumper, headlights, header panel, etc..
Pretty much make it an empty engine bay.

This is probably a good time to swap to a manual rack or plug off the lines on the power one. I’m not sure if there’s a way to make the rack work with the KL pump, but I didn’t do it so I won’t be talking about that.

If you want to keep windshield washers you’ll have to relocate the jug since this wont clear the new engine.

http://kctuners.com/members/inis/mrweeyums/hole.jpg

3rd step, dropping in the new engine.

Hoist in the new engine. It’s a tight fit, but it’ll make it. Be careful of the master cylinder, it comes very close to the hard lines. Bolt in the 2 mx3 side mounts to hold it in place.

http://kctuners.com/members/inis/mrweeyums/Picture%20012.jpg
http://kctuners.com/members/inis/mrweeyums/Picture%20013.jpg

Cut holes in the bottoms of the mx3 a-arms so you can put the nut and bushing on the bottom of the zx2 swap bar end links. Bolt in the a-arms and attach the sway bars. Install the mx3 axles. The alignment will be way off because of the extra half inch length of the a-arms, adjust the tie rod ends to the best of your ability until you can get an alignment.

http://kctuners.com/members/inis/mrweeyums/10-12%20021.jpg
http://kctuners.com/members/inis/mrweeyums/swap%20005.jpg

Attach exhaust manifold and downpipe. It’s easier to not tighten down the manifold to head bolts until the manifold to downpipe ones are started. The zx2 exhaust will have to be cut back to meet up with the V6 downpipe. Luckily, the flange is the same for this aftermarket down pipe and the Kamikaze header I used to run, so it should be the same as the zx2 exhaust but in 2.5” diameter.

http://kctuners.com/members/inis/mrweeyums/swap%20007.jpg

The shift linkage from the zx2 will work, but I had to slot the floor half an inch forward to fit. The slave cylinder hard line will bolt right to the zx2 line.
The throttle cable used is from a 2nd gen Escort. My firewall was modified to take a Focus cable already so it didn’t attach properly, but I believe it will in an uncut zx2 firewall.

http://kctuners.com/members/inis/mrweeyums/swap%20008.jpg

4th step, coolant system.

I used the zx2 radiator spun 180 degrees and mounted infront of the core support. This is only a temporary solution until I can find one that fits better with the outlets in the right places. I had to cut the center out of the header panel to clear this and small pieces of the hard bumper. A custom made or modified civic half radiator might be the best bet. Use a pusher fan from ebay or a parts store.

http://kctuners.com/members/inis/mrweeyums/rad2.jpg
http://kctuners.com/members/inis/mrweeyums/front3.jpg

5th step, fuel.

The top of the fuel pump will need to be drilled and fitted for a return line. I cut the bung off a 2nd gen Escort and welded it on. Use the complete return line from the Escort and run it along with the zx2 fuel and brake lines to the engine bay. The JB Weld in these pics didn't hold so it was later welded properly.

http://kctuners.com/members/inis/mrweeyums/10-12%20017.jpg
http://kctuners.com/members/inis/mrweeyums/10-12%20019.jpg
http://kctuners.com/members/inis/mrweeyums/swap%20001.jpg

6th step, wiring.

This is the majority of time invested. You’ll need to combine the zx2 and mx3 harnesses. The mx3 harness is 90% complete, with just a few relays cut out. The zx2 harness gets basically destroyed. Keep the under hood fuse box and CCRM. The Mazda ECU you use will need to be chipped unless you find a jap-spec ECU for the engine. It runs without but its down on hp and the VRIS points aren’t right. Wire the fuel pump to constant power in the key on position. I wish I could help more in this area but I had a friend do the wiring. As of now, my gauges aren’t working. Ill update this writeup when this problem is solved.

http://kctuners.com/members/inis/mrweeyums/wires.jpg
http://kctuners.com/members/inis/mrweeyums/interior2.jpg

I’m sure I’m forgetting a lot in here, but ill continue to update as I remember.
http://kctuners.com/members/inis/mrweeyums/swap%20003.jpg

~Ryan

[evilescort]

hmm, very nice... post some pics, im interested in doing the swap but im probly gunna megasquirt it instead of using a factory ecu :beer:

[raider]

pics

[Sir William]

Ryan... You my friend are the man!!!

[BlackEscortGT]

So you officaially have the first JDM Zx2? Awesome lol. I wouldlove to get an extra z and attempt this swap but the wireing would drive mw batty.:batnana: good work man. you make what i want to do not seem so hard.

[99fordzx2]

ood job! Now for the videos of it running. Id ove to see 1/4 times. oh and whats the difference between the J-spec and US versions of the motor. Wouldnt it be easier ie cheaper to find a US version in a junkyard?



-D

[MrWeeyums]

Theres a few videos on my youtube. Just seach "klze zx2". The j-spec is 35hp more out of the box, so i figured that was worth the extra $500. Ill have 1/4 times soon once the clutch is broken in and i figure out how to wire the tach.
~Ryan

[ravensguildassasin]

i know this may seem like a stupid question. but wouldn't it be easier to just install digital gauges. ive seen it done on a zx2 before. if done right it will work great and look great. but that's just my two cents.

:edit: i mean replacing the stock gauges in the cluster with new digital.

[MrWeeyums]

i know this may seem like a stupid question. but wouldn't it be easier to just install digital gauges. ive seen it done on a zx2 before. if done right it will work great and look great. but that's just my two cents.

:edit: i mean replacing the stock gauges in the cluster with new digital.

Thats what im working on right now. Ive been talking to zx2fst about his cluster of autometer guages.
~Ryan

[BlackEscortGT]

Now when your done with this how to make a how to on the wiring with your friend.:winkyface:

[ChillinZX]

Nice.

[Buster]

The wiring looks like a messy headache.

Good job on figuring it out. :)

[MrWeeyums]

Credit for the wiring goes to Jeremy, KLDE wagon on here. Theres still a bit to be done with it too.
~Ryan

[ZX2Fast]

Looks like there might be room to put a turbo on it. hehe

I hope you do plan to do something to increase the power output or it really wouldn't make sense to do this swap.

Does it look funny with the front wheels sticking out more then stock?

It is neat that you don't have to weld up or fashion custom mounts for the engine and transmission.

[MrWeeyums]

I hope you do plan to do something to increase the power output or it really wouldn't make sense to do this swap.

I wouldnt really say that. This cost about what full bolt ons and a head package on the zetec would cost, makes more power, tons more torque, and has plenty of room to build. But yeah, i wont be leaving it stock either. Ill most likely be going with a 100 shot unless i come across a really good deal on a turbo or supercharger kit. Their turbo kits mount over the tranny like our gude so theres plenty of room.
The wheels dont really stick out at all. Half an inch on each side is barely noticeable. Only time i noticed it was from the alignment being off.
~Ryan

[ZX2Fast]

My wife pointed out that you are now driving a KX2.

[MrWeeyums]

My wife pointed out that you are now driving a KX2.

:lol: Never thought of that.
~Ryan

[GAZX2]

If i use megasquirt will i have to cut up th factory wiring and use the mx3 wiring? I have everythng but I dont know the schematics and color combos to connect. I have 10 days to get this thing in and going,

will megasquirt be my best option.?

my front end is already gutted as far as body panels and such, i can pull the motor and trans in about 2 hrs

I can set the new motor in in about 2 1/2-3 hrs. The big time consumer is the control arms , axles, tierods wiring, (the first three should take about an hour) Then the plumbing issue

[MrWeeyums]

If i use megasquirt will i have to cut up th factory wiring and use the mx3 wiring? I have everythng but I dont know the schematics and color combos to connect. I have 10 days to get this thing in and going,

will megasquirt be my best option.?

my front end is already gutted as far as body panels and such, i can pull the motor and trans in about 2 hrs

I can set the new motor in in about 2 1/2-3 hrs. The big time consumer is the control arms , axles, tierods wiring, (the first three should take about an hour) Then the plumbing issue

Youre gonna try to do this in 10 days? Any way you go youll have to cut up the harnesses. Mechanically i can see it being very possible in 10 days, if you have all the parts together (i didnt so it held me up). Wiring, i dont see it being possible. Theres a lot of megasquirt support for this engine so thats a good way to go but youll still need the mx3 and zx2 harnesses.
~Ryan

[evilescort]

there is a mega squirt forum that can help you out if you have any problems, so you dont mega squirt in your pants..

[GAZX2]

tru,lol probetalk is alot of help in this area as well as atlantamx3.com

[evilescort]

hey i was looking into your swap a little more and you said you used "82 Chevy Chevette
HEI module" . where exactly dose that go?

[MrWeeyums]

hey i was looking into your swap a little more and you said you used "82 Chevy Chevette
HEI module" . where exactly dose that go?

Its tied into the distributor harness and i mounted it next to the fuse box. Its just an external ignitor for the distributor. Heres a little info on it, i have a better wiring diagram somewhere if u need it. http://www.clubprotege.com/wil/howto/hei/index.htm
~Ryan

[evilescort]

wow, learn something new every day.. i found a possible rolling chassis for my swap, just have to work out a buying price with the guy :)

[tweakfreak]

Do you know what the overall weight difference is between this engine and the zetec?

[DaviDawg]

talking about weight difference. how did this swap affect your suspension/cornering abilities?

[MrWeeyums]

When i started the swap i looked into this and found a few different answers as far as weights, but the difference between the zetec and KL isnt all that much. I just searched around a bit again and the zetec is about 370lbs & the KL about 390lbs. I have my battery in the trunk, no ac, and no ps so its probably lighter in the front than most zx2s. The weight is shifted slightly forward so the balance may be off a bit in that respect. I havent played around in any twisties to see the difference, but its been forever since i have with the zetec. I honestly cant remember what it used to handle like. The front track is an inch wider now too so that also effected the handling in a positive way. I think the only way id know is to drive another zx2 without ps, with progress/tokico combination, and the 19mm rear sway bar back to back.
~Ryan

[tweakfreak]

Hmm, that sound promising. The MX-3 A-arms seem like they fit well minus the hole that needs to be made for the sway bar which is easy. I would think with the additional width and coil overs(cut those things where the stock spring sits in) and you can put a nice fat/wide tire in there.

I look forward to seeing some numbers and videos. Should we start making bets for ET and dyno numbers?

[dmark101]

tru,lol probetalk is alot of help in this area as well as atlantamx3.com
not to drag up an old thread, but that's the first time i've seen PT mentioned on this site. :)

yes, the KLZE is a great addition. i've seen it installed in a couple of different cars, but never in a zx2. i was going to mention using the megasquirt to help with the tuning, but it looks like you have that covered. diyautotune is a great resource for all things megasquirt and they have a forum on probetalk.

[Psychotuner]

W eeyums, if you don't mind, not only for my self but for everyone else Lets look into What you did with the control arms, hubs Axles more. Im thinking the guys who are tying to do the LSD swap can do what you did and just use stock mx3 axles instea dof trying to find someone to make custom axles.

[MrWeeyums]

You could probably use a similar setup with the mazdaspeed lsd, mx3 a-arms, and mx3 axles (and a camber kit of course) but the inner half shaft wont bolt to the zetec block. You would need to make some sort of adapter plate to bolt that down.
~Ryan

[Buster]

You actually used a part from an '82 Chevette? :rofl:

[ZX2guy19]

This car is bad ass. It has a lot of problems...but when it runs, it screams.
My friend is the new owner, and he took out a Chrysler Crossfire the other day. I got to drive it, and I couldn't even get traction in first and sometimes into second. Amazing swap.

[MrWeeyums]

You actually used a part from an '82 Chevette? :rofl:

Yep, thats how custom it was. The ignitors in the kl distributors are garbage so i went with an external one from the Chevette. Saw that mod on probetalk and it worked like a charm.
~Ryan

[Psychotuner]

So to use the MZDspd lsd use Mx3 axles (what year make and modles? ) and control arms and make custom bracket to bolt midshaft down, correct? ? ?

[MrWeeyums]

I replied in the other thread. Wanted to keep this one more about a V6 swap instead of how to LSD the zetec tranny.
~Ryan

[evilescort]

sux i was wantin to buy the car.. guess i'll have to build my own..