Fred's Engine Swap Diary

[Fred]

[Fred]

Put maybe 3 hours total into de rusting my coolant plumbing last night and a few days ago. Working on it again today. Not sure what I'll achieve, but hopefully something.

Also started assembling the FreeEMS ECU for it on Friday night. And a bit last night too.

[Fred]

Achieved lots yesterday:

cam belt and sprockets installed and timed and tested, compression sounds even - 1 hour
took cam cover home and sanded corrosion off of it - 1 hour
soldered new ECU some more - 1 hour

^ took way longer, likely wrong on some of those.

Today so far:

Cleaned silicone off head
installed cam cover with new silicone
cleaned rust off of alternator pulley
installed alternator and wiring to it and oil pressure sensor
various brackets to facilitate the above
flushed out heater core
attached one end of heater core to head
washed down chassis from grease ready for cross member
topped up the oil to full tide mark
cranked and oil pressure took nearly a minute to hit zero again after stopping

3.5 hours

Tonight: maybe nothing, or maybe a little soldering

Knackered.

[Fred]

[Fred]

Cross member torqued up.
lower coolant pipe bolted on with sealant
head outlet hose partially on (hard part done)
heater steel tube straightened and bolted on across back of head and ex side of block
temp gauge and cht sensor plugged in
heater pipe de-ovaled well enough to put a hose on again
adaptor loom in progress

Maybe 3 hours excluding messing around and eating. Thanks to Mike for helping!

Today's plan:

Finish coolant plumbing, minus radiator.
Install turbo and oil feed and oil pressure sensor and oil drain for it
And manifold and wastegate
Install inlet manifold and new fuel hoses
Install engine braces
Install turbo to IC pipe
Replace all vacuum lines with new silicone
Swap CAS loom to new type
Backup hotel ECU firmware and swap to truck firmware
Finish adaptor loom and verify injector and coil phasing possibly with puma board
Get cranking log, fuel pressure, and check timing against firmware
Attempt to start on stale fuel?

[Fred]

Got a fair bit of that done!

Backed up firmware from the hotel and replaced with truck fw from build server
Turbo, ex mani, main coolant pipe, turbo bracket, down pipe, turbo to IC pipe, oil feed, oil drain, all done.
Sway bar end links replaced with fresh ones from SCA.
Truck pulled out, turned around, wheels cleaned, washed and driven back in. Got into THIRD gear... using the starter motor!
Dip stick tube bent to fit gear.
Oil cooler water connections setup.
Radiator washed and flushed out!
Adaptor loom completed by Mike! <3

Pending:

Need to swap CAS plug. Wiring is stripped, but not done yet.
Need to hook up heater core after CAS is plugged in.
Need to tighten vband clamp on downpipe with deep reach 1/4" 11mm socket. Buy this.
Need to tighten the bell housing bolt that was waiting for turbo install.
Fuel system and inlet manifold not done.
Block braces not done.
Radiator not installed.
New vacuum lines.
Wastegate not installed.
Adaptor not verified as correct. Firmware vs wiring pin out not checked to match.
Need to recallibrate firmware for new hardware (MAP sensor especially)

[Fred]

Got it all finished and running

Will add the last few days hours and do an add up at some point soon.