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[05omegav6]

In between dodging heavy rain and my nasty cough, I've got the heads back on, cams fitted and most of the fiddly stuff at the back of the engine connected.
I might get it running tomorrow, which would be good!

Good stuff today was perfect weather for sitting on the drive doing suspension work 

[Nick W]

I once did a gearbox swap in the snow.
Once, and only once.

As for working in the rain; you get used to it.

[05omegav6]

To a point...

[Nick W]

It's now almost done. Plenum is fitted, cam covers/belt/belt cover refitted, SAI disconnected/removed, exhausts cut down(although not refitted), and most of the wiring reconnected.
Lack of light and a family dinner stopped play.

I have just turned a bung for the base of the EGR valve, as that was easier than making a blanking plate. It replaces the tube from the manifold, and is held in place by the original nut cut off the tube.

About the only tricky bit is to remember where all the vacuum hoses attach.

[amba]

Sounds like you had a busy day and the weather held off for you.

I had hoped to get on with the thermostat replacement,but "work" got in the way and wasted my morning messing about with a complicated computer design which then required an afternoon visit to Lower Stoke so nothing mechanical got done here,although potentially earnt a few quid but wont see that until mid/late March assuming all goes to plan and the chippy doesnt cock up 

[Nick W]

Finished it this morning, after losing the will to live yesterday refitting the front pipes on my own, in the rain.
It all looks good, nice smooth idle, no exhaust blow and no tappet noise. There was a leak from the breather box on the plenum, but seating it properly sorted that. A few decent runs are needed to prove the cooling system.

Leaving it running for about 20mins has identified the oil leak. Clean oil directly under the pressure sender and nowhere else means I need to swap it with the one on my other engine.

A new pair of bonnet rams is also needed, I've done most of this work with a stick holding the (bloody heavy!) bonnet open.

[amba]

Sounds like you have been working hard,and not in the best of weather conditions,but glad to hear its nearly all sorted now.

Have a pair of pretty good bonnet rams here if you want them. ..anytime your passing and you see 2 Omegas I am at home just call in and pick them up

[Nick W]

I've now had a chance to use it, and that threw up an unexpected problem; the smooth idle was mostly wishful thinking, and low end power was lacking. So I had a bit of a think, and it seems some idiot managed to connect the #4 and #6 plug leads the wrong way round. Correcting that did return it to normal. The new manifolds seem to have a added a bit of extra punch from around 3500 rpm, so they were £45 well spent. Especially considering that I bought them with the savings from the gasket set.

There's no steam from the exhaust, and the manifolds not blowing makes for a much more pleasant drive. Losing the SAI has tidied up the underbonnet view, although it would be nice to remove the EGR valve, rather than just bung it up.

So, I'm going to call it a success. I'm a little disappointed in just how long it took to do; the same job on an OHV V6 is about 4 hours work in total!

[05omegav6]

Job jobbed, now get indoors and dry out

[jonny2112]

Nice work pal 
And it reminds me I need I suss out my oil leak 
Pressure sender would be a handy fix I imagine out of the options 

[Nick W]

Certainly better than the crank oil seal, which I had bought, and was resigned to doing whilst the cam belt was off. However, I didn't bother, as it was dry behind the pulley. The other possibility was the dipstick tube, which has been proved to be, er, time consuming!

The oil pressure switch is a common fault on the smaller engined Corsas, although they also cause a flickering warning light.

[Webby the Bear]

Nice one Nick... great work!

If the oil pressure switch isn't sealing could you put some thread tape on the threads to seal it?

[Nick W]

Nice one Nick... great work!

If the oil pressure switch isn't sealing could you put some thread tape on the threads to seal it?

If that is the problem, then yes. But it's never been removed, so it's unlikely.
They normally fail internally, and leak from the end. Which means a replacement, and installing the old one in the bin.

[Webby the Bear]

Nice one Nick... great work!

If the oil pressure switch isn't sealing could you put some thread tape on the threads to seal it?

If that is the problem, then yes. But it's never been removed, so it's unlikely.
They normally fail internally, and leak from the end. Which means a replacement, and installing the old one in the bin.