24/01/07
I had the afternoon off yesterday and spent about 7 hours rebuilding the engine. I've been able to identify a few more issues and hopefully, between my Dad and I, we’ve solved them.
I mentioned oil breather differences and like them all the problems I've since encountered are down to the GTA engine being euro 3 compliant where my donor car is euro 2 rather than the engine being a bigger capacity.
Sooo I've used the 2.5 manifold and I
think I can get around the oil breather issues that way, more to come on that later in the year when I fit it.....
First off, I need to replace the 3.2 knock sensors with the 2.5 sensors. The connectors are different. Straight forward to do. No problems.
I'd started putting the injectors, loom and fuel rails back in place when I found my first problem. The 2.5 loom will fit the 3.2 injectors and coilpacks. The connectors are the same which is somewhat fortuitious as to seperate the necessary bits from the GTA loom would be a real PROBLEM.... I wanted to use the 3.2 injectors with the 2.5 fuel rails as the connection from the fuel line is a push fit on the 3.2 and a screw connection on the 2.5. Problem is whilst the 3.2 injectors are the same length as the 2.5’s they will not push home into the GTA fuel rail. Sooo I’m stuck with the 3.2 fuel rail and I’ll have to modify the fuel pipe on the car to fit it.
As I was stuck with the 3.2 fuel rail I had to solve some other issues. The fuel rail is bolted to the intake runners just like the 2.5 but unlike the 2.5 the injectors are held in place and prevented from turning by the clips on the top of them.
The 2.5 is the same but you can turn the injectors around whilst in place, which meant I couldn’t fit the wiring loom on to the injectors. The loom isn’t quiet long enough, (the intake tubes would foul it):
And the connections themselves are too big and foul the cam covers. To solve it the injectors needed to be rotated so the loom could be connected at an angle over a shorter distance just as the 2.5 set up. I reasoned that the clips on the injects are there to hold them in the correct position relative to the GTA loom and not to hold them tightly in place to prevent leaks. That is done by the fuel rail being bolted doen tight. So I removed the clips. Jobs a good un. (hmmmmm…..)
Next up is the thermostat housing. Once again, the wiring loom is different. The 2.5 has 2 sensors where the 3.2 has a multifunction single sensor. I used the 2.5 housing with the 3.2 stat, as I was sure the 2.5 would need replacing. Again, it was straight forward, no problems. The only issue on the cooling side that I can see at the moment is with the coolant feed from the heat exchanger. I need to look at that in more detail.
tha‘s it for now.
This is the way I think I can work it:
Ignore the yellow and magenta connections, they're common to both cars.
2.5:
The red pipe runs from the rear cam cover on to the green pipe.
The green from the rear cam cover to the intake pipe.
The OTHER green pipe at the back runs from the rear of the head through an oil trap to the manifold. The oil trap drains back to the rear vent on the rear cam cover (red pipe). This doesn't exist on the 3.2. No oil trap and no rear bank vent at the back.
My version (see page 1 for 3.2 setup.....)
So on this one I connect the green pipe to the intake pipe as the 2.5 and take the vent from the front bank to the inlet manifold.
*thinks about it.
I wonder if I could have used the GTA manifold? [:s] [:$]
