Prepping as dedicated track car - Page 63 - Mazda 6 Forums : Mazda 6 Forum / Mazda Atenza Forum
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post #621 of 641 (permalink) Old 12-12-2015, 08:45 PM
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It is a classic course. Catching air over the apex of the second ess has got to be, umm, clench worthy.

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post #622 of 641 (permalink) Old 12-26-2015, 04:56 PM Thread Starter
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Back to work on the Beast!

The 2016 season is coming and there is work to do.

Back in Sept we broke the right axle at VIR.
We have a worsening engine oil leak.
We need a windshield defroster if we're gonna run VIR in February.
Need to decide what to do about our ABS speed limiter hack.

Here's our broken axle - pretty sure there are supposed to be some balls in there.


Here you can see the alternator and everything above it is wet with oil.



It looks like a combination of several leaks - the valve cover gasket, the OCV seal and the OCV housing itself is leaking. I've ordered all the parts.




Waitin on parts.

CR

2003 Mazda 6s MTX
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post #623 of 641 (permalink) Old 12-26-2015, 05:03 PM
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Waitin on parts.

CR

That's usually the hardest part.
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post #624 of 641 (permalink) Old 12-26-2015, 05:47 PM
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where did u get the ocv seal?

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post #625 of 641 (permalink) Old 12-26-2015, 08:21 PM Thread Starter
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where did u get the ocv seal?
Napa #NOS-10930

Not OEM, but the dimensions a VERY close. I'll let you know how it goes.

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post #626 of 641 (permalink) Old 12-27-2015, 01:56 AM
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Thanks~!

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post #627 of 641 (permalink) Old 12-27-2015, 05:33 PM Thread Starter
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OK got some parts! Got the valve cover off. Here's the right valve cover. You can see the OCV seal is in pretty rough shape - in fact part of it is still on the OCV.



Here's the old seal on the right, the new seal on the left and the Napa part number on the box.



The rubber seal fits very nicely on the OCV. The shell of the seal is not quite as tight in the valve cover as the OEM seal. You still have to tap it in but it doesn't require much force. I added a VERY SMALL amount of RTV in the valve cover where the seal sits. This will provide a little more sealing peace of mind.



Then tap the seal in with a socket that matches the shell.



Flip it over and notice a bit of the RTV squeezed out. Clean it up and don't get any on the rubber seal.





Ready to put it back together.

CR

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post #628 of 641 (permalink) Old 12-27-2015, 05:46 PM Thread Starter
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I got the new axle shaft installed with new boots, axle seal and fresh gear lube. Moving to the interior. Our next event is in February. I've run in Feb before and besides being cold in the car with no heat and no windows, its really hard to see with no defrost. So I salvaged this out of an E36 BMW.



It is an all electric heater/blower for the rear window. I bench tested it and it outputs over 100deg air. Awesome! Now we need to mount it.
I removed the dash and steering column and found a place I think will work. I made a bracket that points it straight up to the base of the windshield directly in front of the driver.



I'm planning to install a full rollcage, so I'm not re-installing the dash. Made some more brackets to mount the gauge pod.



Still some cleanup and wiring to do.

CR

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Last edited by CanyonRider; 01-06-2016 at 11:30 AM.
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post #629 of 641 (permalink) Old 01-10-2016, 06:20 PM Thread Starter
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Ended up doing both valve covers with gaskets and OCV seals. Since the intake was off I figured I'd upgrade the throttle body. I picked up an optimized 3.7L TB (73mm vs 63mm on the 3.0L) - with a broken throttle stop. I also have a stock 3.7L TB for parts.

Here R to L is 3.0L TB, stock 3.7L TB, tapered TB spacer/adapter.


Here is the optimized TB. The TB stop is broke off and stuck inside. The replacement is sitting on top.


The threads are plastic and has thread locker on it - it is not intended to be adjusted or serviced. Inside the plastic threads is a spring and plunger.


I carefully drill out the plastic without damaging the threads. Then use a tap to clean out the remaining plastic.



I apply thread sealer (not locker) and insert the new stop. It is adjusted such that when the butterfly is fully closed, the stop plunger is full depressed. Then we install the TPS from the 3.0L TB.


Install the manifold and TB.


Ready to make a couple more HP.


CR

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post #630 of 641 (permalink) Old 01-11-2016, 01:57 AM
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where did you purchase your tapered TB spacer/adapter?

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