Now we've made it to today. The day my parts arrived and I started the first timing belt job I've ever performed on a Miata. I've owned a hand full of the cars but always subbed the job out. I may again. It wasn't hard but it sure was arduous.
The car was already torn down quite a ways from my investigations. Valve cover was off as the car came with a new valve cover gasket and needed it. I had removed the belts and water pump pulley on my way to checking the crank key way. Also I had removed the timing belt covers to check the tensioners and belt condition.
So next I changed out the water pump. No surprises there. I was glad I didn't have to remove the cam gears because...that was scary. Also, they wouldn't hold still for me to loosen the bolt that held the gears to the cam. If you want pics of this procedure just check out miata.net. They have as many pictures of timing belt changes and water pump stuff as Reddit has pictures of girls with their boobs out. Wait a min..you're already clicking on reddit.com aren't you? It's ok. I'll wait.
While working on the water pump I remembered how some folks had real trouble removing the woodruff key and front crank seal. In a moment of genius I ordered the front crank seal too. The front of the engine looked a little grimey so I thought I'd replace that as well. So..as a diversion from some water pump action I reached down and gave the woodruff key a tug. It came right out in my hand. Same with the timing gear. Cool. I completed the water pump and moved on.
I changed out the timing belt without any issues. Timing the cams was a cinch as they wouldn't budge from their current positions unless I really heaved on them with the ratchet. That made lining up the timing marks really simple. I set the tensioners and reinstalled the crank timing gear and woodruff key. When reinstalling the crank pulley I did wring off one of the m10 bolts. I was stupid...too much he-man torque on one and off the head came. I then removed the crank bolt I had just torqued to 150 ft lbs and looked at the broken bolt. I remembered that you could cut a line in what was left and use a screw driver to try to back it out. I pulled the dremel and started cutting. It worked great. I was as surprised how easy it came out once I tried that technique. I reinstalled, restrained my over torquing habits, and all went on nicely.
I started reinstalling everything. All the accessories like the alternator and power steering pump. Put back on the timing gear plastics. Reinstalled the belts. Reinstalled the valve cover with a fresh gasket. Put in the new thermostat and realized the supplier didn't put in a new gasket. I thought "Maybe if I bolt this up tight enough it won't leak?" I then progressed to reinstalling the air hose, radiator, and fans. It went pretty quick actually. During this process I replaced the two sensors that threw codes originally.
Then, the moment of truth. The car was put back together. I had charged the battery a few days before. I sat in the drivers seat and ignored the cigarette butts lodged in the carpet near the emergency brake. I turned the key to start and it fired up. Just like that. It ran like a top. In my enthusiasm I got up and looked under the hood and saw the thermostat housing was leaking all over the place. After driving to the parts store and getting the one gasket ($2.36) I installed it. I then restarted the car and decided to try to go for a test drive. The brakes had to work in some way right?! Wrong. I got to the top of my driveway and decided against it.
So...backed down the driveway and started on the master cylinder install. Which was frustrating because the hard lines were in the way of the right side mounting bolt. Eventually, it went on. But had a lot of air in it because the supplier didn't think I would need any fittings to bench bleed it with. I installed it as bled as I could get it and then bled each corner of the car at the caliper. I tried using the Harbor Freight hand vacuum bleeder. It worked about as well as trying to cut cheese with a piece of string. I then resorted to the old style Harbor Freight one man bleeder and that worked great. I pumped some fluid through and built some pressure at the calipers. While doing this I noticed one of the wheels has a cracked spoke. Time to shop for a replacement.
It was time for the first test drive.
...and it was glorious.
The car drove well. It needs an alignment but the power was there. The trans shifted great. The clutch held power well. I couldn't tell if the pads are worn as I completely forgot to look but there was some grumbling sound under braking. The interior still smelled like a dirty ashtray but I'll get to that later.
So it runs..and runs well now. Time to source the other parts to make it a more comfortable and presentable ride as well as one I can take to HPDE's. I cleared all the engine codes and they haven't come back. My bet is those two sensors...would've got it running right away. But at least now I have the piece of mind of knowing that the Tbelt, water pump, etc are all done.
tl;dr - fixed the car. runs great now. grandoise ideas of the future commence.