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Old 04-22-2013, 04:13 PM   #1
Xeroni
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Default David's BlacknWhite 765

*Engine swap starts on post 6*


Guess I should start one of these to keep me on track for what I want to do in the future.

My current 1990 765 Turbo. Which I didn't take any pictures of when I bought it.
I got her for $1000 at a tow yard down in Redwood City. Checked all the fluids, inflated the tires, and drove her home that day.

I replaced all the wires, plugs, cap, rotor, air fliter, changed oil to Delo 15W40, timing belt, and got it smogged. Passed once I was told of a place that didn't fail for any little thing (thanks to Magnum TE).

Next up was to make it a little bit louder. I removed the rear muffler and put a pipe in it's place. I couldn't wait to start working on it. Did some research on here and started buying parts. First up was new IPD sport springs and some Sachs Advantage shocks. I grew tired of trying to clean up the Omega wheels so I decided to plastidip them.
http://imageshack.us/a/img854/8043/wp20130210001.jpg

Both electric seats in the car were pretty beat up and neither of them moved. So I grabbed a friend and went to Pick n Pull on a 1/3 off day and picked up two manual cloth seats from a 87 740.

http://img826.imageshack.us/img826/9...0130215002.jpg

I don't like chrome. I probably should of just got a 740 instead. So I had a few cans left over from the wheels and did this to the trim.

http://img29.imageshack.us/img29/387...211001copy.jpg

Next came a manual boost controller to turn up the boooost and a AEM wideband to make sure I didn't blow it up. After that I decided that it still wasn't loud enough and had a exhaust shop replace the cat back section with a straight pipe. Hockey puck motor mounts and transmission mount were done somewhere in here.

http://imageshack.us/a/img29/8245/wp20130317005.jpg


And last Friday 4/26/13 me and a buddy replaced my stock T cam with a slotted A cam I bought off ebay.

http://imageshack.us/a/img404/581/wp20130419002.jpg
http://imageshack.us/a/img191/4334/wp20130419007.jpg

And how she currently is:
http://imageshack.us/a/img826/2994/wp20130422001b.jpg
http://imageshack.us/a/img855/6271/wp20130422002.jpg
http://imageshack.us/a/img689/3250/wp20130422008.jpg
http://imageshack.us/a/img716/8872/wp20130422010.jpg
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Last edited by Xeroni; 03-24-2014 at 01:42 AM.. Reason: images too hueg
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Old 04-22-2013, 04:28 PM   #2
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Videos:

With the back muffler removed


With both removed on T cam


Boring driving video


With A cam


Hot A cam idle

Last edited by Xeroni; 04-22-2013 at 04:34 PM.. Reason: MORE VIDEOS AAAAAA
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Old 05-16-2013, 12:26 AM   #3
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Windows were tinted 5% at Davis. Got a 15g from a 850 at pick n pull. Went back to get the flange and found a 740SE.

http://img594.imageshack.us/img594/8...130510002k.jpg
http://imageshack.us/a/img690/5200/wp20130515008.jpg
http://imageshack.us/a/img208/4844/wp20130515003.jpg
http://imageshack.us/a/img545/337/wp20130515005.jpg
http://imageshack.us/a/img841/9516/wp20130515006.jpg
http://imageshack.us/a/img442/1492/wp20130515007.jpg

And I apparently overfilled my tank today. Put in 14 gallons and saw this when I started it.
http://imageshack.us/a/img690/3797/wp20130515001.jpg

Last edited by Xeroni; 03-24-2014 at 01:42 AM..
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Old 09-23-2013, 01:48 AM   #4
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3in turbo back to a 18in Summit glasspack side pipe.



Let me roommate drive it to work, not the best idea.



New exhaust gaskets and found a crack in the manifold.


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Old 12-18-2013, 09:03 PM   #5
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my side exhaust got squish also :P
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Old 03-19-2014, 12:58 AM   #6
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Sadly the wagon caught fire yesterday. No injuries other than the car. I suspect the injector o-rings failed since I smelled gas before it happened.

My plan is to swap out the engine/transmission and transplant it into the 740 that's sitting engineless in the garage. It'll require a 2.4 harness swap since the reason the 740 didn't run was because of a bad harness. We're going to pull a complete 2.4 harness on Thursday/Friday and get it ready for surgery.

The fire:












And today I started the tear down/holy crap so much melted plastic/I can't breathe.









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Old 03-19-2014, 08:56 AM   #7
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sorry to hear about your car fire! so what are you doing with the kit on the 760?
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Old 03-19-2014, 02:17 PM   #8
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It's going on the 740 of course.
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Old 03-20-2014, 04:22 AM   #9
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740 harness has been pruned of all fuel and ignition related connectors and wires. Still need to give the crossmember and bay a good scrubbing. And get that passenger motor mount out so I can put my early solid styles in.

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Old 03-21-2014, 01:48 AM   #10
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Had a wonderful 4 hours at Pick n Pull today.

Got a list of things:
Intake
Throttle Body
Throttle spool and linkage
Fuel rail and clips
Oil separator
Knock sensor
Coolant temp sensor
Crank position sensor
940 efan
2.4 fuel/ignition harness from a 240
Oil dipstick
Transmission dipstick
16v coil
intercooler
Timing belt tensioner
850t injectors

The cabin half of the harness is installed and the crossmember is clean and ready for the early solid mounts that I've had for months.

We're going to have to repair the cabling to my wideband but luckily there is a bunch of extra in the cabin so soldering so go easy.

Engine hoist has been borrowed and we just have to disconnect the driveshaft and mounts on the wagon before we lift it out.

About to start looking at the wiring diagrams to see what I'll need to connect between the two harnesses.
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Old 03-21-2014, 01:55 AM   #11
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Hope the swap goes well. Nice work!
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Old 03-21-2014, 02:20 AM   #12
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Thanks Luke. I've enticed a few friends over with offers of BBQ and beer. We hope to have the engine in tomorrow and it running some time next week and it driving before Davis.
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Old 03-22-2014, 05:12 AM   #13
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Much work done today, or well, Friday. We started around 2pm.

Engine working it's way out.


Darren disconnecting power steering lines.


Engine in it's resting place of a few hours.


Putting the oil pump gear back in after switching intermediate shafts so I can run a block mount distributor.


Hockey puck motor mounts waiting to hold the engine.


My friend Brett being unamused with how long it is taking us.


Engine being lined up for the final drop.


Things that were replaced:
Alternator
Distributor
Starter from a Kjet 240
New seals on the crankshaft and intermediate shafts

And there's a bunch more that needs to be done. But we decided to call it a night after the engine was put in at 1230am.
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Old 03-23-2014, 01:18 AM   #14
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Horrible night shot.



Didn't so much today after work, waiting for parts to come in. Motor is bolted it, new intake and gasket, new fuel rail hooked up, new coolant temp sensor, and I timed and put a belt on it.

Currently needs:
Injector o rings
V belts
Transmission crossmember put in
Driveshaft from wagon put in
Harness sensor and power/etc plugged in
New kickdown cable
Radiator transmission connectors swapped to new radiator
Timing belts covers
Transmission linkage bent back straight and connected to gear selector
Interior (will probably be done later)
All suspension swapped from wagon to sedan
All exhaust swapped
Put gas in it

The second half of the Rockauto order will be here Wednesday so I'll be working around the engine waiting for the parts to come in.
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Old 03-24-2014, 01:52 AM   #15
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Mounted the efan in the stock shroud using exhaust rubber hangers on top and bottom with zip ties to hold it in.



Mockup of SE front bumper on, will have to get creative with the side mounting points. Had to also swap the bumper shocks for shorter ones.



Found a o-ring replacement kit for four injectors laying in my tool chest. No idea how they got there. Routed the wiring harness under the intake and over to the battery and plugged in most of the stuff.



Test fitting the rad and fan. Looks like I'll need to get some studs for the water pump pulley to clear it.

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Old 03-24-2014, 07:27 PM   #16
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Get regular hex head bolts for the water pump pulley
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Old 03-24-2014, 08:27 PM   #17
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I think my harbor freight bolt set might even have the right length. One trip to the store saved.
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Old 03-25-2014, 04:08 AM   #18
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So the 940 efan doesn't leave enough space for my liking. Less than 1/8 in between it and the water pump pulley itself with out the bolts. Going to have to find a shorter fan that fits better.

I installed the transmission crossmember, put in the cooler and hooked up the lines for it, installed the turbo and downpipe, moved the distributor to the driver side, installed the wires (and corrected them after I took the picture), put a gallon of 50/50 Zerex G-05 and distilled water in.

All I have to do now is hook up the alternator, starter, battery, vacuum lines, and intake hoses and it should run. Need to go buy some more water, various vacuum lines, and give the bay a good scrubbing.



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Old 03-26-2014, 04:27 AM   #19
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No pictures today, mostly stared at it thinking of what I wanted to do next...

I did remove both driveshafts and put the auto one in the 740 and the M46 one in storage in case I ever need it. Everything but the rear bumper from the SE kit is on the 740, the kit came off a wagon so there wasn't a rear lip unfortunately. Also cleaned the garage out so I could find the rest of my tools...
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Old 03-29-2014, 01:18 AM   #20
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Some pictures of the filthy engine and bay:

90s GM FWD fan, fits perfectly on the rad. Can also see the sensor I put in the rad which switches at the correct temperature.



New headlight!



Cold side maf ()



Stripped interior and a bunch of wiring I have to clean up.


Last edited by Xeroni; 03-29-2014 at 01:32 AM..
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Old 03-30-2014, 01:02 AM   #21
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Someone didn't put the seals in right.

This guy.



Efan works automagically though.



That pan full of oil was from the oil change I just did, not what leaked out fyi.
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Old 03-30-2014, 02:40 PM   #22
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you can get a rad / intercooler from a 940 .. they are inside the rad support far from the engine not like the 740's which are closer so the clutch fan is closer to the rad
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Old 03-30-2014, 03:47 PM   #23
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Yeah but then a NPR intercooler wouldn't fit as easily.
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Old 04-01-2014, 03:55 AM   #24
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Fixed the crank seal yesterday, was pushed in too far.

Swapped over the passenger side suspension from the 760 to the 740. Replaced the strut mounts with JY units. Good thing too, the old ones were starting to crack.

A week of sitting and a few days of rain makes a rotor look bad:



In serious need of cleaning, and the bumper sides need to be attached:

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Old 04-01-2014, 04:12 AM   #25
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(son)


Looking good dude! I like the SE bumper on the old front end, don't believe I've seen it before.
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