Andrew's '93 NA6 - KL V6 swap

[Beelzeboss]

Just finished reading this thread from start to finish (it took two nights) - I'm lost for words. Makes me regret even more that I didn't switch from electrical engineering to mechanical when I had the chance...

Regardless of how this ends up, kudos for having the guts to even try it. Keep going, especially now that you're so close!

Thanks very much LiteIsRite, I really appreciate your comment It really is a long read, what with all the changing my mind and redoing mistakes, but it's very nearly finished.

I haven't contributed to the thread but I have subscribed and I'm always keen to read it when I get the update notifications!

Thanks Tim, it's good to hear people are actually reading what I'm typing. Sometimes it just seems like I'm sending it out into nowhere and I'm the only one who's reading it

Well on Wednesday night my mate Bryce came over to help prep the engine for install and to change over the diff.

At about 5pm (started very late) it looked like this



Then we set about the diff and rear brake swap.



Old diff vs. new





Empty subframe



No pics of it installed, unfortunately, but we got it in and bled the rear brakes. By this point it was 1:30am... so we decided that since the engine isn't actually difficult to install now that we've done it a few times, we might as well just install it.

So...

Bryce on the crane







It's in!





The PPF was pushing the gearbox waaay over to the passenger side for some reason so it took a solid 2 hours of busted knuckles and shoving the engine to get it intalled, but it's done!

Does anyone know why the PPF would be moved over with the new diff? I'm thinking maybe if I loosen the bolts at the diff and gearbox they'll align themselves? At the moment the gear lever is about 2" over to the passenger side to give you an idea of the problem.

[Veloce]

Sweet fit and looks so much space too!
Can't help about the offset.
Another subscribed fan, started early in the build.

[manga_blue]

Can't think why the PPF is forcing you over there. I thought both B6 and BP diff housings use the same PPF, Normally you just loosen all bolts at both ends of the PPF, set the gearbox in place vertically, centre the shift lever hole and then tighten it all up. If the gearbox alignment is out by a little bit then there's a bit of a chance of vibration from the propshaft.

Did you know about the gearbox alignment spec?

[LiteIsRite]

I know you've got your hands full at the moment getting everything lined up but, when you get a chance, I'd like to know why you settled on 13" wheels - it's not that common, and I'm surprised that the standard NA6 brakes fit, let alone NB8As. Looking forward to seeing them on the car...

[Beelzeboss]

Sweet fit and looks so much space too!
Can't help about the offset.
Another subscribed fan, started early in the build.

Thanks Veloce, there really is heaps of room in front and behind the engine. On the sides... not so much, lol

Can't think why the PPF is forcing you over there. I thought both B6 and BP diff housings use the same PPF, Normally you just loosen all bolts at both ends of the PPF, set the gearbox in place vertically, centre the shift lever hole and then tighten it all up. If the gearbox alignment is out by a little bit then there's a bit of a chance of vibration from the propshaft.

Did you know about the gearbox alignment spec?

Thanks Manga. The problem was I didn't loosen the diff side of the PPF when we put the gearbox on. I loosened it all up and retorqued them and it's all good now. Next to no shifter offset
That diagram is very good but I'm not sure how high the crankshaft of the V6 sits in relation to the 4 cyl, so it could be off by quite a lot. If I have any vibration I'll try changing the angle and making a note of it.

I know you've got your hands full at the moment getting everything lined up but, when you get a chance, I'd like to know why you settled on 13" wheels - it's not that common, and I'm surprised that the standard NA6 brakes fit, let alone NB8As. Looking forward to seeing them on the car...

Well I chose the 13" wheels because I think they look awesome, they're much lighter than 15" wheels, they're pretty rare, and if I want cheap track tyres I can get a set of slightly used 13" Avon slicks from a formula ford

The good news is the car is completely back together and I bought a new TPS sensor. However, it turned out to be a ground loop in the system which I JUST found tonight, so now I have a spare TPS.
The bad news is the car is still blowing white smoke The head was perfectly flat, it's a new gasket, new ARP studs... the only things I can think it might be is excess moisture just burning off (only ran the car for ~10 mins), the block is warped, or the 3 month old E85 in the tank has absorbed so much moisture that it's making white smoke yet still running. I think it's unlikely the block is warped because I checked the sealing surface with a straight edge and couldn't see light under it in any orientation... Ideas?

[manga_blue]

Ideas?

Compression test. Compare all cylinders. Dry and with oil.
CO test in coolant.
Any chance of coolant entry into the inlet manifold rather than the head?

[Beelzeboss]

Ideas?

Compression test. Compare all cylinders. Dry and with oil.
CO test in coolant.
Any chance of coolant entry into the inlet manifold rather than the head?

Thanks Manga, I can't see how coolant would get in via the inlet manifold. I'll do a compression test at some point

For the moment I bought a cheap K8 engine (1.8L V6, externally identical to the 2.5L) which I'm going to throw in and get rego. Since it's within 15% size and power of the original 1.6L engine and I havn't had to modify the car at all to fit it, I don't need to get it engineered. The KL will go in when I have time and have fixed the stupid head gasket issue.

[16bit]

they are from the old 323's right?

[16bit]

thats an over square engine, should build a custom flat plane crank and rev its tits off!

[vass]

Words of encouragement

After following this for many months all I can say is, I wish my boys had the get up and go in them that you do.

Power to you and your tenacity to start a project like this and see it through. So many times do you see and hear of people who, with the best intentions start something and then abandon them at the first hurdle.

Good on you and thanks for shining a bit of positive light on the youth of today. I hope my children read this and become as inspired by this as much as I have (although there is no chance of that because its not on television or in a computer game LOL!).

All i can say is 'Excellent, excellent, excellent"

[LiteIsRite]

Power to you and your tenacity to start a project like this and see it through. So many times do you see and hear of people who, with the best intentions start something and then abandon them at the first hurdle.

Well said... couldn't agree more

[manga_blue]

I can't see how coolant would get in via the inlet manifold.

I can't either but I don't know the engine. Some V engines have coolant running through the inlet manifold, meaning there are water passages between the head and manifold.

[Beelzeboss]

they are from the old 323's right?

thats an over square engine, should build a custom flat plane crank and rev its tits off!

This one is from a Eunos 30x but I think they were used in 323's too. All K series are way oversquare with good rod ratio's, the only things stopping them from revving to the moon is the hydraulic lifters and mild cam specs. I'd love to convert to shim under bucket and get a proper cam for it, maybe later on down the track. I also found out that since it's an identical block to the KL, you can put the KL crank and rods in it to make a 2.0L engine, and you can also safely bore out the engine to accept KL pistons and then put the KL heads on to make it identical to the KL

Words of encouragement

After following this for many months all I can say is, I wish my boys had the get up and go in them that you do.

Power to you and your tenacity to start a project like this and see it through. So many times do you see and hear of people who, with the best intentions start something and then abandon them at the first hurdle.

Good on you and thanks for shining a bit of positive light on the youth of today. I hope my children read this and become as inspired by this as much as I have (although there is no chance of that because its not on television or in a computer game LOL!).

All i can say is 'Excellent, excellent, excellent"

Wow, thanks vass! That's the sort of praise which makes me glad I kept going with the project I appreciate it

Well said... couldn't agree more

Cheers

I can't see how coolant would get in via the inlet manifold.

I can't either but I don't know the engine. Some V engines have coolant running through the inlet manifold, meaning there are water passages between the head and manifold.

Ah I see, yeah the KL doesn't have any coolant running through the intake manifold. I just helped a mate install a supercharger on his commodore ecotec, until then I'd never seen an engine where coolant went through the intake manifold.

Well I'm picking up the K8 engine (and attached Eunos 30X) on Monday. Today I unbolted almost all the bits and pieces from the engine in preparation for removal and also welded the final pieces onto the intake pipe. I made a bracket to hold the Bosch/BMW idle control valve I bought from the wreckers, and I also pretty much finished the washer bottle which is the final part to be made for the car All that's left is to remove the exhaust and make the brackets which hold the washer bottle... and swap in the K8 engine of course.

[Beelzeboss]

Well the 1.8 is in, running well and I discovered that it was the E85 causing the white smoke so there's nothing wrong with the KL motor (I think)





I also replaced my broken electric window switch with 4 cheap relays and a couple of jaycar mini switches. I've yet to zip tie the relays up under the dash, but they work perfectly.





A much cheaper alternative to those expensive, hard to find window switches.

I have a few things left to do on the car before blue slip but I'm going to book it in for next week

[NitroDann]

Mad.

Mad props for the whole build really If i havnt said it yet.

Dann