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[JamesV6CDX]

I've had this project sat on my drive for six months now and haven't really done anything with it, but now the lighter evenings are coming, I'm going to be dusting it off, and getting it done this spring

In a nutshell, it is a very, very tidy black Saloon CDX, starting life as a 2.6:









Unfortunately, the 2.6 engine lunched itself, seemingly due to oil starvation. I still haven't got to the bottom of why this happened. But what better excuse to put another 600cc under the bonnet?

The old 2.6 engine, I removed a few weeks ago, like so:





Because I'm putting in a 3.2, the AR25 auto box on the 2.6 is going to have to be binned, as the 3.2 will destroy it.

I have decided that, on the 3.2, I am going to do the most thorough job possible on it. Every gasket and seal will be changed, including the front and rear crank seals. It's also going to be cleaned so that it's absolutely squeaky clean. The only things I am not touching is crank/pistons/rings - as it's a low mileage engine and they just don't fail. I am going to rebuild the heads, though, lapping in all the valves, and fitting new stem seals.

(That reminds me, I need to source a 2-4-6 head, as we used the one off this project to get BigTime on the road) - I think I have a suitable one on my 3.0 V plate - but not sure where I've put the camshaft shells 

I have absolutely loads of new genuine parts for it. This includes oil cooler, Cambelt kit, HBV, aux belt.... basically, you name it, it's being replaced

I have dropped in the 3.2 lump, but at the moment, it looks a bit like this!



As you can see - much cleaning required!

When I dropped this in it had the heads, Cambelt etc fitted, however having removed the 2-4-6 head to help another member, on Friday evening I stripped the rest of it, so it's ready to be cleaned.

I dropped it in without the gearbox, just because I haven't yet got an AR35 to fit on there. I'm undecided at this time as to whether I use the AR35 off my old Elite, or to source another. The one from the Elite is fine - when I first fitted it to the Elite, it had a bit of a jerky change into top gear at high revs - this disappeared over time so I put it down to the solenoid, rather than a mechanical issue... 

But then I have also been toying with the idea of manualising it!! A black, manual 3.2? 

I do generally prefer the V6 as an auto, though...

Anyway - watch this space. I'll be using this thread to update with progress. I will basically just be doing a little bit at a time, at my enjoyment.... certainly not a rush job...

I may also LPG it when it's running

[Shackeng]

A nice looking car James for a worthwhile project.

[Nick W]

Looks good, but I'm often puzzled why people fit half engines like that, and fit them up once in the car - it seems like really hard work to me.
It's much easier to build the engine as far as possible on the stand(or bench, or even the floor if absolutely necesary) and then crane the whole lot into the car, including the gearbox where possible. I've fitted engines complete right down to the fanbelt, which just left wiring it up and bolting on the air filter.

[JamesV6CDX]

Looks good, but I'm often puzzled why people fit half engines like that, and fit them up once in the car - it seems like really hard work to me.
It's much easier to build the engine as far as possible on the stand(or bench, or even the floor if absolutely necesary) and then crane the whole lot into the car, including the gearbox where possible. I've fitted engines complete right down to the fanbelt, which just left wiring it up and bolting on the air filter.

I totally agree, and would have loved to have done it that way...

However the logistics for me, is that I only have a single garage, and due to space needed on the drive, the car is half in the garage, with the front out in the open air for me to work on.

I was also using a borrowed engine crane, which I only had for a limited amount of time, and, because the car was already half in - half out of the garage at the time I took delivery of the new engine... It would have meant storing the new engine outside in the elements and, although we live in a reasonable area - potentially accessible to thieves.

So, I take on board your point - but, the reality was, I have to work with the facilities I have, and had to do the heavy lifting work while I had the crane available to me...

[Nick W]

Garage? What luxury, I do all my stuff in the street!


The last engine I did, the 1275 A-series in Deb's 1300, was assembled on the back court and fitted to its gearbox.


We then carried the assembly through the house, and up the cellar steps. I bolted on the manifold and carb, alternator, engine mounts, radiator etc, while Richard assembled the crane and jacked the car up so that the crane would go underneath. Another 20 minutes saw the engine swung into place, bolted down,the driveshafts refitted and the bonnet bolted back on. That lot was enough for one evening, as I don't get home until 20:30, so we went for a beer.

[Shackeng]

Good plan, and fairly simple to carry a 3.2 + gearbox.

[kevinp58]

Good plan, and fairly simple to carry a 3.2 + gearbox.

If you have the free use of an elephant 

[Varche]

Garage? What luxury, I do all my stuff in the street!


The last engine I did, the 1275 A-series in Deb's 1300, was assembled on the back court and fitted to its gearbox.


We then carried the assembly through the house, and up the cellar steps. I bolted on the manifold and carb, alternator, engine mounts, radiator etc, while Richard assembled the crane and jacked the car up so that the crane would go underneath. Another 20 minutes saw the engine swung into place, bolted down,the driveshafts refitted and the bonnet bolted back on. That lot was enough for one evening, as I don't get home until 20:30, so we went for a beer.

You have lived when two of you install that engine and gearbox without a crane. Just  two straps. Youth of today don't know luxury.

[kevinp58]

Garage? What luxury, I do all my stuff in the street!


The last engine I did, the 1275 A-series in Deb's 1300, was assembled on the back court and fitted to its gearbox.


We then carried the assembly through the house, and up the cellar steps. I bolted on the manifold and carb, alternator, engine mounts, radiator etc, while Richard assembled the crane and jacked the car up so that the crane would go underneath. Another 20 minutes saw the engine swung into place, bolted down,the driveshafts refitted and the bonnet bolted back on. That lot was enough for one evening, as I don't get home until 20:30, so we went for a beer.

You have lived when two of you install that engine and gearbox without a crane. Just  two straps. Youth of today don't know luxury.

I did a Vauxhall viva HC engine on my own  mind you I was a lot younger and stupid 

[Nick W]

Garage? What luxury, I do all my stuff in the street!


The last engine I did, the 1275 A-series in Deb's 1300, was assembled on the back court and fitted to its gearbox.


We then carried the assembly through the house, and up the cellar steps. I bolted on the manifold and carb, alternator, engine mounts, radiator etc, while Richard assembled the crane and jacked the car up so that the crane would go underneath. Another 20 minutes saw the engine swung into place, bolted down,the driveshafts refitted and the bonnet bolted back on. That lot was enough for one evening, as I don't get home until 20:30, so we went for a beer.

You have lived when two of you install that engine and gearbox without a crane. Just  two straps. Youth of today don't know luxury.

I've done enough Mini/Escort/Capri/Avenger engines with a rope and a scaffold pole when I was young, stupid and didn't know any better. £200 for an engine crane is money well spent and makes such jobs both easier and safer. It also means that crazy ideas involving 500ci Caddilac engines become viable.

[biggriffin]

Fit 2.5 cyl heads, 3.0 downpipes.

[JamesV6CDX]

Fit 2.5 cyl heads, 3.0 downpipes.

I have the 3.0 downpipes here, but..... 2.6 heads?

Compression ratio aside, you'd have to use the 3.2 gasket, to accommodate the bore size, Id' think - so it wouldn't sit "straight" around the fire rings, on a 2.6 head? 

[Steve B]

That will be three cars you have james when this one is finished,  So which one you going get shut of.  I vote the big beast

[JamesV6CDX]

Seeing as the sun's decided to come out, I thought I'd make a bit more progress on this, yesterday, so I went and removed the AR35 autobox from the Elite, which is being stored at my mum's place around 70 miles away.

That was all I was planning to do, but I made good time and was home by 3pm, so thought I may as well take advantage of the lighter evenings and get the thing fitted whilst I was still dirty!!

Here she is going on to the project:





As you can see by the pics, easy enough to fit an autobox with the car on axle stands. I did this one on my own with the gearbox sat on a trolley jack, on a rubber mat to stop it slipping around.

I have to say, the job would be made a million times easier with two people. The hardest part of it for me, was lifting the gearbox up into the back of estate to bring it home, and then lifting it back to the ground to fit it. But needs must, seeing as I was working as a billy-no-mates!!

[JamesV6CDX]

For anyone unaware, (as the pics don't show it - I didn't fit the torque converter to the box until it was under the car)

The correct way to fit these boxes is to locate the torque converter inside the bellhousing first, and fit it as one unit. There is an access hole in the engine block, to then get the bolts through and bolt the torque converter to the drive plate. This makes life a million times easier and greatly reduces the risk of damaging the seal on the gearbox shaft

[EMD]

Hats off to you james for doing all that on your own  Take it easy though .

[Shackeng]

Agreed, when we did mine between us, I made the tea, passed the spanners, and did all the swearing while James did the work. Seemed a very satisfactory system.

[JamesV6CDX]

Today consisted of me starting work on the project... And then....

Going arse over tit whilst climbing in the engine bay, crashing down on the windscreen, hurting my shoulder, and smashing the scuttle

I walked away for half hour, and started again!!

Over the last few days ive had off, I've removed the heads from my 3.0 which are very clean and in good order. I've ported out the inlets on the heads, fitted new stem seals, and re lapped all 24 valves.

Today I fitted the (new) oil cooler and pipes, breather box, heads, exhaust manifolds, camshafts, rear timing cover, cam pulleys, water pump, Cambelt kit, and outer cover. Thermostat, link pipe and B bolt also fitted...

That was enough for one day... I'm getting there

[JamesV6CDX]

The broken exhaust manifold down pipe stud delayed me a tad.

Pleased with the repair though

[Steve B]

The broken exhaust manifold down pipe stud delayed me a tad.

Pleased with the repair though

Is that my old one james 

[elvin315]

Am I wrong, or wouldn't this be a perfect candidate for a hot rodded V6?

Starting with your 3.2L V6 as the core long-block), swap the pair of 2.6 liter V6 heads onto it (using the 3.2L's head gaskets). To make the most of the increased compression, the 2.6 heads must be ported slighty to mimic the contours of the 3.2L/3.0L head's intake passages so to match their airflow specs. Then swap the 2.6L's intake and exhaust camshafts with 4 intake ("G") camshafts from the 3.2L and/or 3.0L engines (both motors use the same "G" intake camshafts). Those cams, plus the exhaust valves from either the 3.0L or 3.2L (sodium filled for better heat transfer), are the hot set-up (no pun intended......maybe?).

Next we use the 2.6's fuel delivery setup (injectors, fuel rails) but with the 3.7 Bar Fuel Pressure Regulator from the 3.2L. That combination makes for finer fuel atomization and an improved flame-front. The 3.2L's stock ECU and sensors will work fine with this hodgepodge engine and though it should be safe to use regular grade gas, I suggest mid to high grade gas. It will protect the pistons by preventing pre-detonation, and exploit the increased potential of the engine.

I got this info from members here but If I'm wrong I apologize.

[05omegav6]

2.6 fuel rail, inlet manifold and injectors are identical to 3.2 ones... upping fuel rail pressure sdimply makes the ecu cut injector times as it won't overfuel itself 

[elvin315]

My mistake. I thought the 2.6 fuel rails and injectors were same as the 3.0's which I'm told are better.

[JamesV6CDX]

I have offered 3.2 head gaskets up to 2.6 heads.....

With the gaskets on the dowels eg where they would be... The fire rings do not sit centrally at all

I wouldn't be comfortable with 2.6 heads on a 3.2...

[Kevin Wood]

Do you have a photo of this?

[JamesV6CDX]

Do you have a photo of this?

No but I have a 2.6 head and 3.2 gasket here, so I will take one and upload it

[Kevin Wood]

Do you have a photo of this?

No but I have a 2.6 head and 3.2 gasket here, so I will take one and upload it

That would be handy.

[EMD]

Agreed, when we did mine between us, I made the tea, passed the spanners, and did all the swearing while James did the work. Seemed a very satisfactory system.

I thought he liked lots of Coffee 

[JamesV6CDX]

Agreed, when we did mine between us, I made the tea, passed the spanners, and did all the swearing while James did the work. Seemed a very satisfactory system.

I thought he liked lots of Coffee 

Depends on how much sleep and / or beer I've had the night before!!

[JamesV6CDX]

Getting there!



You'll note the lack of AC compressor. The AC system is being fully overhauled, so that's only a temporary measure.

Since the above pic, I've refitted wiper motor, scuttles, wipers, the inlet and plenum and associated pipework is also all connected up... as is the engine loom

Outstanding jobs are, plus in the connectors under the car, fit the cats, (I have ground off the lips on the downpipes) and the propshaft, also the battery terminals and wires... and fill with fluids.

I will naturally cross check everything, but I THINK that's all that's needed before I Can turn the key...... watch this space over the next couple of days

[JamesV6CDX]

Getting there!



You'll note the lack of AC compressor. The AC system is being fully overhauled, so that's only a temporary measure.

Since the above pic, I've refitted wiper motor, scuttles, wipers, the inlet and plenum and associated pipework is also all connected up... as is the engine loom

Outstanding jobs are, plus in the connectors under the car, fit the cats, (I have ground off the lips on the downpipes) and the propshaft, also the battery terminals and wires... and fill with fluids.

I will naturally cross check everything, but I THINK that's all that's needed before I Can turn the key...... watch this space over the next couple of days

It's too dark for a proper pic, but this is where we are after today's tinkering:

[Diamond Black Geezer]

Absolute joy to watch this taking shape, and made me realise there's lots more for me to do on my old girl!  Keep up the good work

[JamesV6CDX]

It runs!!!!!!

Sweetly.

Currently have a fault light due to the secondary lambdas not being installed - need to weld on  bosses. But they don't affect fuelling so no rush

[Sir Tigger KC]

Awesome!    Well done James!! 

[VXL V6]

I notice you've done the aux heater bypass modification, presumably in preparation to gas it?

That's as far as I've got with my LPG conversion LOL.

[JamesV6CDX]

I notice you've done the aux heater bypass modification, presumably in preparation to gas it?

That's as far as I've got with my LPG conversion LOL.

Well spotted

There is now no longer a 90deg angle joiner, I used the top HBV to heater matrix pipe from my breaker, so it now looks totally standard

I need to put a new aux belt pulley on there. That's noisy despite being greased.
The mid sections are also not lining up brilliantly with the cats, there is a small blow. I need to sort that. Although in reality, I might just pop a new exhaust on, so that's renewed.

Can we still get them from eternal car?

Also, is there anyone on here who could cut two holes and weld 2 x lambda bosses for me please? I'd rather it be done on the car, than removing the cats, if at all possible.

Happy to travel, and goes without saying, to pay...

[JamesV6CDX]

And in terms of gas - it's a possibly. I quite likely will, tbh.

Where are we buying the kits from these days?

[05omegav6]

Stag kits still readily available, and if you find the vapouriser or injectors a bit light weight, they are readily upgraded either before installation or after, once it's fitted

[Shackeng]

I notice you've done the aux heater bypass modification, presumably in preparation to gas it?

That's as far as I've got with my LPG conversion LOL.

Well spotted

There is now no longer a 90deg angle joiner, I used the top HBV to heater matrix pipe from my breaker, so it now looks totally standard

I need to put a new aux belt pulley on there. That's noisy despite being greased.
The mid sections are also not lining up brilliantly with the cats, there is a small blow. I need to sort that. Although in reality, I might just pop a new exhaust on, so that's renewed.

Can we still get them from eternal car?

Also, is there anyone on here who could cut two holes and weld 2 x lambda bosses for me please? I'd rather it be done on the car, than removing the cats, if at all possible.

Happy to travel, and goes without saying, to pay...

I think Serek does this James.

[JamesV6CDX]

A few minor niggles... but a 70 mile roadtest tonight and overall I'm quite chuffed....

[joff]

And in terms of gas - it's a possibly. I quite likely will, tbh.

Where are we buying the kits from these days?

I have a front end kit in the parts shed with plenum and inlet manifold

[JamesV6CDX]

And in terms of gas - it's a possibly. I quite likely will, tbh.

Where are we buying the kits from these days?

I have a front end kit in the parts shed with plenum and inlet manifold

If I'm honest, LPG isn't the highest thing on the list.. but, just so I know - could you confirm what version of Stag ECU it is, what Vaporisor and injectors... and the approx mileage it's covered? And of course the asking price

Given the new kits are cheap as chips I was probably going to go that route... but I'd like the info so I can keep my options open.

Thanks again Joff for donating this block to me...

[Steve B]

Well..... Is it on the road Yet....

[omegod]

When you inevitably get bored with it ,and if it's gassed, give me first dibs please

[JamesV6CDX]

It's in a position whereby it's perfectly safe and legal to drive... but still needs a few tweaks, which I've not been able to sort largely due to time

1) There are still no rear lambdas to measure cat efficiency. So the fault light is still on for this.

2) I have two fault codes I can't get rid of. P1600 "PCM BATTERY" and P1625 "TCM FLASH CHECKSUM FAULT (Saturn).
I have checked and double checked all wiring, all of the round plugs near the battery, everything is as it should be.
I think also linked to this code is the fact that the gearbox is (half of the time) holding on to it's gears for too long before changing.

3) I need to fit a new multiram actuator for the rear multiram. The one on the car was snapped off when it arrived. The car doesn't have too many guts up until 4000 rpm. (But pulls like a train afterwards)

4) The exhaust is shoddy, and makes an awful pattern-part sound. I need to replace this.

5) There is, annoyingly, a lifter noise from startup. When first started, it's quiet as a mouse. After a couple of mins the lifter starts tapping. But then when it has been driven for a bit, the noise disappears again. I've put some wynnes in there.. I think I will try a few short oil changes before I start ripping it apart. It's just an isolated lifter and I am sure it's on the 2-4-6 bank.

6) I've changed the rear crank seal... but the front one is also shot, weeping nicely. So I will be changing that in the near future.


Just a few jobs to keep me busy.

After that - suspension overhaul!!!!