Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Will deBeast

With the lovely weather now here, it was a perfect day to get the mx-5 out of the garage.

I was volunteering on the local steam railway for the day, so roof down for the 30 mile trip there. Simply blissful.

On the way home, I stopped at a roadside shop to buy some asparagus - the first we've had this year. Pulling out, the engine light popped on - amber. The engine still ran fine, so I drove home as normal.

Got home, read the code. It seems to be the stepper motor that operates the EGR valve. I've deleted the code, but expect it'll return. £500 repair apparently - it's horrible to get to - between the engine and bulkhead. Removing the wiper motor, etc. It set me thinking about taking the car to BBR for a performance upgrade - surely they must delete the EGR as part of the work. I'll sell it to the wife as a better investment than £500 at the dealer!

So ... a lovely day out slightly spolied. And the first 'breakdown' in 10 years of MX-5 ownership. Though it did at least get me home.

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - craig-pd130

Can you still get those bolt-on supercharger kits for the MX-5? I'm sure those would involve an EGR delete too ;-)

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Will deBeast

Leaning towards new exhaust manifold and an ECU remap. £1195 + VAT + fitting.

I need to fine tune the man maths though, so that becomes £1100 (plus a wee bit) vs £500 at the dealer.

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - John F

Heigh ho - the perils of modern car ownership. Got the SORN'd TR7 out to run it up and down the drive and prepare it for next month's outings. Amber warning light appeared as usual on the dash. Easily extinguished by adjusting the wire operated engine management unit (choke).

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Engineer Andy

Can you still get those bolt-on supercharger kits for the MX-5? I'm sure those would involve an EGR delete too ;-)

Not sure if it involved the latter, but Jason from Engineering Explained on YouTube added a bolt-on supercharger to his gen-4 MX-5, and after a false start, it seems to be working very nicely. He's covered it in a couple of videos.

www.youtube.com/user/EngineeringExplained/videos

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - moward

I wouldn't be parting with £500 unless it actually does return. On the other hand, if you really want that BBR upgrade..........

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - groaver

What extra bhp will it give you, Will deBeast ?

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Will deBeast

Quite modest - BBR claim 24 bhp & 18 lb.ft of torque.

The standard car is 158bhp, so about 15% more.

bbrgti.com/products/bbr-super-180

There's a little more power available by changing the rest of the exhaust - but that puts the cost up even further, for only a further 5BHP.

Edited by Will deBeast on 16/04/2021 at 16:23

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - groaver

The boost in torque lower down the range should make it feel quick.

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - skidpan

Modern N/A petrol engines do not respond well to re-mapping like a turbo does. To get more power you need to burn more petrol in more air, in a N/A re-map all they can do is change to ignition timing and injection settings to the absolute optimum but the gains are small, 15% is their claim, reality may be different, read the small print.

But modern engines do have a lot more unrelased power available simply because they are strangled by emission kit, noise regs and packaging issues. With the correct parst there is plenty of gain to be made.

Take the 2 litre Focus Zetec in the Caterham. Ford claimed 134 PS for this engine (132 bhp). I removed the fuel system and replaced it with a Jenvey twin 45mm throttle body set up on a special manifold (looks like a pair of Webers) fitted with Weber Marelli Pico injectors (as used on the V twin Ducatti superbikes) breathing through a pair of K & N cotton gauze filters. The fuel is fed using a high pressure Walbro pump (same as used on mapped Scoobys), the HP pump being fed by a low pressure Facet red top pump and swirl pot. The injection and ignition is looked after by an MBE mapable ECU ( as used by several low volume manufacturers) and a custom engine loom. The Ford exhaust manifold was junked and replaced by a 4 into 1 tubular set up into a 2 1/4 " silencer.

This set up allows plenty of fuel in, plenty of air in and a free flowing exit for the waste gasses.

Not cheap by any means but I was able to sell off many of the surplus parts from the Focus engine plus parts my previous twin Weber 45 set up with Weber Marelli ignition. Net cost was in the region of £1500.

The result is 175 bhp, 41 bhp more than standard, about 31%. There would be more available if time was spent optimising the cam and ignition timing on the dyno but the cost per bhp would become daft at this point.

But its only relevant to older cars where the emission rules do not demand all the OEM kit be fitted to the car. My Caterham is classed as prev 1974 so basically there are no rules.

But having said that, this engine, whilst being way more powerful than an old x-flow on carbs also uses way less fuel thus logic says its a lot cleaner.

If work needs doing go ahead but have a good drive in a converted car and read the small print first.

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - skidpan

The boost in torque lower down the range should make it feel quick.

Not if the extra torque is high up in the rev band in an area where it rarely reaches

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - groaver

"The 'Super 180' equipped 2.0i MX-5 produces an impressive 24 Nm (18 lb.ft) more than the original, with peak torque of 159.6lb.ft arriving at just 4250rpm, some 750rpm lower than the stock car."

I read the brochure. ;-)

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Steveieb

Could this problem be exacerbated by the use of supermarket fuel ? And would HJ s cure of a regular tank of Shell V power help ?

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Will deBeast

Could this problem be exacerbated by the use of supermarket fuel ? And would HJ s cure of a regular tank of Shell V power help ?

Unfortunately not. The EGR valve seems rarely to go wrong. It's the stepper motor that drives it which causes the issues.

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Will deBeast

In the end, I decided that I didn't want to pay the garage £500. And didn't really want to splash out on the upgrade. So I decided to fix the fault myself.

I can see why Mazda charge £500. The EGR comes as one unit, and changing it is a pig of a job - either drop the gearbox out, or use a special mazda tool.

I was fortunate in that my code was only for a faulty stepper motor. The motor is attached to the mechanical part of the valve with 4 set screws. It is tight, but you can just about get to the stepper motor by stripping the car back. Though smaller hands would have been helpful.

My stepper motor was branded 'Ford', rather than 'Mazda'. I bought an as-new Ford EGR off eBay (from a crate engine), and fitted the stepper motor. Total cost £40. And about 5 hours of my time.

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - groaver

Good job done with the satisfaction of knowing the "grease monkey" did the job right!

Mazda MX-5 Roadster Coupe - Car sulking after lockdown - Roger Hulme

My light came on today but I drove home - a distance of about 30 miles. I didn't drive fast as recommended in the handbook - no more than about 40 mph.

Everything else was working normally. You said you read the code when you got home. How does one do that? I have the car serviced by a Mazda specialist about 20 miles away but was thinking of taking it to a local garage where I take our other cars. Would they be able to diagnose the fault?