Squig's CDX v6; WIP

[Colorado]

Thatsa big shame

[Squig]

Today and yesterday I've been preparing to rip the engine and gearbox out to change to an F28... now before I go further I'll point out the last engine swap I did in a 4 pot was done and gone in 2 days but this v6 is beating me down... that and Em and I have spent a day finding the turbo gearbox mount, clutch, gear linkage and F28 amongst the piles of parts I've acquired over the years. Whenever Gaz is down he usually can find something he wants, even if it's my turbo rear clusters (which he's not having )... so now I've located the turbo bits I'm cracking on, slowly

So far all the electrics and plumbing have been separated from the engine, the suspension has been split, exhaust is off and the drive-shafts are ready to be removed from the 'box. However on these engines it would appear that the air-con compressor must be unbolted from the mount and the power steering pump needs to have the lines disconnected both of which may require a contortionist to remove...

Another problem has been tools... I have what I'd consider a suitable collection to work on Vauxhalls if nothing else, but I've never had to use a 15mm spanner, as a result when I lost it I never got around to replacing it.
Today I needed it!

Bugger...

Anyway I started yesterday with loads of pics, but today spending a good chuck under the car groping around grease, road dirt and oil (really need to do the steel cam covers with ANOTHER new set of seals) I had no room, never mind inclination to get piccies, so the How2 maybe a little sparse on pictures I'm afraid.

For those of you thinking about attempting this you will need a full set of metric spanners from 8mm-19mm and sockets ranging the same... otherwise you will not get the engine out.

Anyway, tomorrow Gaz said he'd pop over to supervise (translated as kicking my arse into finishing this ) so roll on the 6 speed 6 cylinder Cavalier!

[Squig]

oooh... what a day... engine out gearbox off. Problems, problems, problems... the v6 gear linkage mount doesn't mate too the F28 and will need modifying, the Courtenay lightened fly doesn't fit with the f28 and the bolts securing the clutch cover doberry to the fly don't fit the turbo fly... yeesh...

so for those of you that are planning this I'd suggest do your research first. I will do a How2 but I will need someone to clarify whether the standard v6 flywheel will fit the F28.

sorry decided to knackered so I'm off

[Squig]

Feeling good today as the F28 is in and the original passenger side driveshaft fits perfectly, which indicates the spacing is correct (fit the rear mount to the same position on the F28 as on the F25, space the passenger side mount by 12.5mm, or as close as, and space the engine mount by 23mm). No major issue to report other than the equal length driveshaft on the drivers side, due to the shift in engine position, no longer mates to the block so I've decided to try a non equal length item which I'm happy will fit based on the gearbox size and fitment of the shorter shaft... however I may end up with some torque steer

Anyway I just need to finish plumbing wiring and fit a heat shield and the exhaust and we're running again. I believe a shaft from a cav 2.0 or possibly a 1.8 should fit and take the torque. So a scrapyard run is being done tomorrow ...


...in a 1.6 auto mk2 golf...

oh and the bolt size on the turbo fly to clutch plate are 7mm, I used engineering bolts, the original gearbox bolts need to be spaced and I can't wait to be finished!

Nitey

[Colorado]

Sounds all under control!

[Squig]

All together today... but appears the clutch got put on backwards so we have to drop the gearbox and sort that but I expected something to go a little askew and really, although it's fairly major, it's an easy fix...

So quick summary of required parts;

• F28 - either mechanical or electronic depending on your clocks, electronic clocks can use either type though...
  F28 gear linkage,
  F28 clutch plate/cover,
  Turbo clutch plate,
  1.8/2.0 8v one piece drivers side driveshaft,
  Spacers - 3 x 23mm & 2 x 10mm, or some thick M10 washers,
  Bolts - 6 x M7x25mm, 3 x M10x140mm (here I would advise the M7's can be aquired with the F28 fly, as these are used to fasten the clutch assembly to the fly, and try and get the gearbox to engine bolts to as the V6 items will either need shortening or spacing.

Parts modified to fit correctly;

• V6 gear linkage mount to gearbox - re-drilled hole nearest the block approx 8mm further back towards rear gearbox mount.

Parts I had to change due to aftermarket parts fitted;

• Lightened flywheel changed for turbo flywheel - I had a Courtenay lightened item which caused fouling issue with the shallower bellhousing.

Total costs approx £300-350 inc gearbox and other F28/turbo parts

[Squig]

the above smilie describes my day... all together and fluids done but need to adjust the cable owing to the clutch not fully disengaging when the pedal is fully pressed in.
ooooooh... annoying... more so is that I only found this out firing the car at 6:30pm as Em's uncle came round today for a hand changing the clutch on his punto , horrible job due to the gearbox having to come off to change the clutch too.

once again

[Envoy CDX]

Bad and smelly

[Gaz]

http://www.migweb.co.uk/forums/items-sa ... tings.html

you seen these squig?

[humbucker]

you seen these squig?

beat me to it!

[Squig]

Honestly I hadn't but I would probably recommend getting in touch with him if you do want to do the conversion as the driveshaft will probably cost just as much...
Well little update... I've given the v6 a 25 mile run today and found some problems...

1. I'd forgotten to connect some minor things which were causing running issues, a sensor, the jubilee clip for one of the heater hoses... the bottom radiator hose... D'oh!
2. The balance weight on the new driveshaft had to be removed owing to catching on the alternator, hence recommending looking into the above part.
3. The reverse lights seem to stay on continuously even with the plug removed.
4. 3rd on the F28 has a bad whine, not pleased about that but looking into having it sorted whether I buy and replace the faulty part or exchange the box and some cash for a recon'd unit.
5. The rubber boot on the passenger driveshaft has been split and replaced but seems to have dumped the new grease over the inside rim on the wheel I appears to have missed the inside cable tie...
6. The cav now seems to heat up at a ridiculous rate... (sorted the hose issue and checked for airlocks)
7. I have codes 25 and 42 on the ABS fault chart, due to forgetting the toothed ring on the new driveshaft...
8. I NEED a new clutch cable.

Problems 1 and 2 are dealt with and were sorted prior to the run, number 3 has been temporarily sorted by removing the bulbs, 4th is waiting on a call monday, 5th will be fixed tomorrow, 6th is a puzzle and 7th & 8th will be sorted monday when I get home.

Sorry to all you guys who wanted pictures but this job had me at points ready to use the lump hammer in a destructive manner so having a conveniently smashable object close would have been a bad idea.

Plus point tonight thou, I couldn't resist having Emma timing a 0-60 run in the passenger seat and I'm pleased to report a result of 6.8 seconds, I know I should be being gentle until every niggle is sorted but I couldn't resist!

[Colorado]

Sometimes the last thing you want to do is take pictures. Still got plenty to do.

[Squig]

got a quote for the fully reconn'd 'box from JR Dain, recommended F28 specialist from cav16.co.uk... £500 for labour and parts on my existing box... a fair price but, Wow!
So on to tomorrow and checking the box over, levels and stuff as I did top up but maybe not enough... new clutch cable is half done as I've strained my left hand doing the gearbox, and I'm suprised how much I use it.

[Squig]

Right clutch cable was done a while ago and the gearbox is all good but attending the meet today the v6 chewed a sensor wire and now the car is in limp home mode... gutted... so I fitted the omega bonnet lifers

[Envoy CDX]

Right clutch cable was done a while ago and the gearbox is all good but attending the meet today the v6 chewed a sensor wire and now the car is in limp home mode... gutted... so I fitted the omega bonnet lifers

That's not good which sensor?

[Squig]

crank...



...but I may have a spare, so I'll have to go digging through the shed... however the cav will be off the road for a week or so as I will be without insurance (new insurer and wasn't expecting the deposit... I'll explain that in a minute) so hoping to do a proper in the air check and adjust and hopefully get some new wishbones as during the gearbox change I buggered the ball joint rubbers. Also I expect the crank sensor to require a fair bit of digging so a few weeks of strandedness gives the perfect excuse to sort all the little problems, maybe touch up some of the stone chips and clean the small amounts of rust under the bonnet... might even wire brush and hammerite the belly too...

On the insurance front I got a winner phoning around... £370ish with lower excess on windscreen and the same everywhere else (except valued more), instead of £1050 with Direct line or £417 with Adrian Flux... only I've filed the details and can't find them now

[Envoy CDX]

Ouch, my cav won't even start without the crank, so think yourself lucky lol
Theres a chap that sells the rubber boots 10 for £2 or something, Arthur Daley - quick in sending stuff out too

[Squig]

checked on the spare v6 and the sensor is the knock sensor... and I have a spare so it's all good, not done yet as been helping terry out but shall crack on tomorrow

[TurboDan]

Who's that insurance quote with?

Try swiftcover.com, i'm with them on my Turbo and i pay about £480 fully comp and i'm 24 with 5 years no claims. So you should get your nice and cheap with them

[Squig]

found the quote it's £329 or £358.64 total if DD.

[TurboDan]

Bargain!

[Squig]

Bad day...

Broke the CC/Accelerator cable mount...

They MUST be mounted using a pair of washers, or it will disintegrate at some point...

Mine has!

No pics I'm afraid as I kind of lost me rag and launched the bits.

[Envoy CDX]

It'll be fine once you sort a replacement Don't worry bout it too much

[TurboDan]

lol, i don't get it, you mean then two 10mm bolts that hold the accelerator cable in place too?

[Squig]

No Dan just were the CC cable clips throu... but I'm happy atm because I'm now insured!

Still need to fit the ABS compatible drive-shaft and the wishbones and track-rod ends... but the insurance got done first and I reasoned the split rubbers were only done as the F28 went in which meant I could get the parts in the v6, which lead to a motorway blat and to a friends gaff and consequently to no work having been done
Whoops...
Oh and a side trip to the bodyshop where Emma, Dan and I baited Gaz... you know that ecotec isn't going to cut it against the v6, just admit it.