Omega Owners Forum
Chat Area => General Discussion Area => Topic started by: RonaldMcBurger on 28 July 2007, 20:25:48
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Firstly, I must say a HUGE thanks to laidback who spent the whole day here lending me one hell of a hand! :y
Right. Replacement engine arrived at 7pm last night, so dumped it on my drive under a tarpaulin for the night and started work on it this morning. The donor engine is from a 1998 car with almost identical mileage. This one had DIS pack failure due to slight problem with the HBV - see pics!!!
So, work required today before the engine goes in was as follows: Remove manual clutch and dual mass flywheel, then spigot bearing. Remove both exhaust manifolds and fit new gaskets. Remove both camcovers and replace gaskets. Remove faulty DIS pack and replace. Remove faulty HBV and replace. Remove entoire wiring loom and replpoace with mine with LPG attachment looms. Replace FILTHY plenum. Clean all breathers right through.
I started at about 9am. Fisrt job was to examine the engine closely for anything else suspect. Decided to go ahead with transplant, so stripped the plenum off followed by the aircon compressor and alternator off. Removed the whole loom. then removed the inlet manifold to inspect the coolant brifdge and ooil cooler areas. Next was the drivers side manifold gasket. Very easy with the engine out. removed the only heat shield on that side which was the upper one. Obviously removed the bidg coolant pipe too. Got manifold off and the gasket was blown as you will see in the pics.
Then cleaned up the manifold mating surface thoroughly and lightly cleaned the cylinder head surface too. On with the new gasket, fitted the top heat shield after cleaning up a bit and put the ccolant pipe back with a new seal. OBTAINED BOTH THE LOWER HEAT SHIELDS AND FITTED THEM TOO
Next was the passenger side manifold. A b@stard of a job even with the engine out. Problem is access to the lower front bolt. The dipstick and coimpressor mounting are in nthe way. So, off with both of them too! Also removed the whole engine mounting frame for beter access still. This gasket was also gone, so glad I did it.
Then put everything back on that side before starting on both rocker gaskets. Drivers side was ok, but had been bodged with some blue sealant. Passeneger side was awful. Oil is quite filthy and will take a few flushes to clean up properly. Lack of maintenance again. Did both rocker covers and renewedc the covers themselves with better ones.
Then put the wiring loom on and alternator, aircon compressor etc.
Finally removed the clutch and dual mass flywheel. Had to spend nearly an hour smashing the spigot bearing out, but got there in teh end. Fitted auto flywheel and everythging torqued up.
Dave and I then reassembled the engine crane and hoisted it up and in. Actually took about 10 minutes to get the engine in.
Dave did the engine mountings up and we then started on mating up the gearbox. This just didn't work this time and I ended up accepting defeat for the day. I will try tomorrow if I am up to it.
The nengine will be sweet as a nut when done. The gearbox is now an AR35 and should outlast the AR25 by miles. The car will live again very soon. Hopefully it will be running tomorrow.
Pics to follow in a mo.
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CLICK PICS TO ENLARGE
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0127.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0127.jpg)
That blue sealant someone used on the drivers side cam cover!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0126.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0126.jpg)
This is the worst failure of a HBV I have seen!!!!!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0125.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0125.jpg)
As a result of the HBV failure, the dis pack had a regular shower. Hence which it too died.
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0124.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0124.jpg)
The passneger side cam cover seal was 100% gone. Oil filled all the plug wells and was seeping out the top!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0123.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0123.jpg)
The cause of that camn cover seal failure and a sign of things to come. The breathers are blocked hence this crap in the throttle boddies
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0122-1.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0122-1.jpg)
The engine before I started
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0121.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0121.jpg)
A close up of that HNV BEFORE I started work!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0120.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0120.jpg)
And how it looked on the engine
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(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0129.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0129.jpg)
Drivers side exhaust manifold leak
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0131.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0131.jpg)
And cleaned up
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0128.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0128.jpg)
manifold before and....
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0132.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0132.jpg)
After
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0137.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0137.jpg)
That heater Bypass Valve problem!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0136.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0136.jpg)
Both rocker covers off
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0135.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0135.jpg)
Passenger side manifold access!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0134.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0134.jpg)
manual flywheel removed
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0139.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0139.jpg)
New rocker covers and gaskets
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0141.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0141.jpg)
then new DIS pack, new leads, new HBV
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0145.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0145.jpg)
One engine bay, minus engine. Gearbox is waiting patiently on the ground. Glove is to stop dirt getting in!
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0140.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0140.jpg)
One Laidback + one engine. Behind Dave is my Mrs CDX Estate and over the road is project 18, the 2000 CD Auto.
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0142.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0142.jpg)
Engine now off the ground again
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0144.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0144.jpg)
And from a different angle with Dave
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0143.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0143.jpg)
And closer
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0146.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0146.jpg)
In it goes
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0147.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0147.jpg)
And in
(http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/th_IMG_0148.jpg) (http://i40.photobucket.com/albums/e219/ronaldmcburger/Elite%20LPG/IMG_0148.jpg)
Lots of wiring and plumbing to sort AGAIN !!!!
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Christ allmighty you make it sound like a piece of Pi** :y :y
looking forward to the pics, did you do the vid to it too??
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It was easy!
Didn;t do the video, camcorder battery flat, tape ran out, errrr........... I forgot! :-?
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It was easy!
Didn;t do the video, camcorder battery flat, tape ran out, errrr........... I forgot! :-?
Oh break, thats a shame, was looking forward to that :'( :'(
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Well done the pair of you :y Can i have some of them tablets that allow you to work on cars Fin, cos mine just make me want to have a sleep ;)
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Congratulations :y :y
lucky for you the sun was out :y i bet it`s better in a t-shirt rather than an anorak ;)
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Was that the famous Harry Potter in the photos... ;D ;D ;D
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Thats a good days work Fin. What was stopping you fitting the gearbox? have you checked the dowels....might have them in both engine and 'box.
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No, I did think that Pete. Just wouldn't go on properly. Could be forced on with the bolts, but then crank would not turn by hand. Took it back off tonight. I will try tomorrow but judging by the level of pain tonight, that may be off the cards too.
I suspect the torque convertor just didn't home properly into the dogs. Seemed fine, but I cannot think of anytthing else.
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Was that the famous Harry Potter in the photos... ;D ;D ;D
Indded! :y
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Well done fin a good days work.Have a good soak and rest then if your up to it hit the thing again tomorrow and the box will prob go stright on first time.
Gary. :y
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No, I did think that Pete. Just wouldn't go on properly. Could be forced on with the bolts, but then crank would not turn by hand. Took it back off tonight. I will try tomorrow but judging by the level of pain tonight, that may be off the cards too.
I suspect the torque convertor just didn't home properly into the dogs. Seemed fine, but I cannot think of anytthing else.
Hi Fin,
I had exactly the same problem fitting my box on the 3.0 - it mated up with help from the bolts, but couldn't crank the engine at all by hand. It turned out that the TC wasn't quite on it's dogs either - I pulled the box back, lined up the TC in the box, and persuaded it in with a rubber mallet ::)
I'm sure that's your problem
Cheers
James
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Right then. 11:07 and I now have a second Jack. Quick cuppa and I'll get started on this sodding box again. Anyone got a stopwatch. bear in mind, today is single handed and I ache like F&%$
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Ta Da!!!
1hour 25 SOLO gearbox fit.
pics in a bit. Pressing on now.
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Ta Da!!!
1hour 25 SOLO gearbox fit.
pics in a bit. Pressing on now.
Was it the Dogs then?
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No it is this sodding car. JINXED!!!!!!!
Just taking the box back off AGAIN now. You wouldn't adam & eve it.
Put box on, can crank engine by hand great. Line up the first torque convertor bolt hand tight, crank to the next one and so on. All 6 in and do up the first one. THIS WAS A MISTAKE! By doing up that one, the torque convertor is pulled in to the flywheel that last bit. BUT, now the other bolts are sticking out slightly by the same amount, so when you now try and turn it, they snag on the block.
Loosened box, freed up flywheel after a LOT of grunting and swearing. Did it all up, now it won't turn again.
So, back to where I was at 9am again.
I have absolutely no doubt whatsoever that this car is the worst nightmare I have ever dealt with as far as cars go. Everything that can go wrong has.
Fed up now. >:(
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No it is this sodding car. JINXED!!!!!!!
Just taking the box back off AGAIN now. You wouldn't adam & eve it.
Put box on, can crank engine by hand great. Line up the first torque convertor bolt hand tight, crank to the next one and so on. All 6 in and do up the first one. THIS WAS A MISTAKE! By doing up that one, the torque convertor is pulled in to the flywheel that last bit. BUT, now the other bolts are sticking out slightly by the same amount, so when you now try and turn it, they snag on the block.
Loosened box, freed up flywheel after a LOT of grunting and swearing. Did it all up, now it won't turn again.
So, back to where I was at 9am again.
I have absolutely no doubt whatsoever that this car is the worst nightmare I have ever dealt with as far as cars go. Everything that can go wrong has.
Fed up now. >:(
Do you want a hand? Obviously, as a favour..
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Thanks James, but dave is here. We just have to put it on the same way I did this morning, but do the torque convertor up immediately. Damned annoying car from start to finish. ANY more problems and I WILL scrap it. I am on the last chance with this car now. So near I don't want to give up, so annoying I do!
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Thanks James, but dave is here. We just have to put it on the same way I did this morning, but do the torque convertor up immediately. Damned annoying car from start to finish. ANY more problems and I WILL scrap it. I am on the last chance with this car now. So near I don't want to give up, so annoying I do!
This is the sort of work that really grits you hope all goes well this time :y :y
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Gearbox all done again. my fault for not doing the TC bolts up tight first time round, just an old habit of doing the round to get the bolts in then tighten down once they are in. just the logistics mean this is a nightmare.
Thanks to Matchless for the loan of his jack again. You really do need two GOOID jacks for this. Easy peasy then.
More write up later.
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Gearbox all done again. my fault for not doing the TC bolts up tight first time round, just an old habit of doing the round to get the bolts in then tighten down once they are in. just the logistics mean this is a nightmare.
Thanks to Matchless for the loan of his jack again. You really do need two GOOID jacks for this. Easy peasy then.
More write up later.
Or a car lift, and a gearbox lift... ...even easier ;D
So all one now then? All sorted?
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Ronnie - a great read and even better pictures :) well done ( to everyone in involved too)