your car looks awesome benj, the dohc install will really top it off! i

BA DOHC 30.1 - Install Prep - Remove BARRA from test car

Hmmmm, what does this mean?





Date for install is 24-26 August 2012.

Over the next 3 weeks I have a number of tasks to be done in order to be ready.

• Paint block with engine enamel
• General clean and tidy of engine
• Replace rear main seal
• Replace front timing case seal
• Flywheel - clean, machine and install
• Spigot bearing - install
• Install turbo sump
• LPG - Drill and tap BA BBM for injection nozzles
• LPG - Fabricate injector manifold mounts
• Wiring Loom - Final wrap of engine bay loom
• Wiring Loom - OBDII port install
• Welsh Plugs - install new in rear at least
• Install new water pump - maybe

I am sure there are some other things I have missed.

Game Plan

I have the Friday off work and will begin in the morning by removing the front and rear bumper bars so I can drive the wagon down onto the flat part of my driveway. The angle is too steep to negotiate with the bars on the car and those of you who have seen it in person will understand LOL.

By the end of Friday I would like to have the EL Engine and T5 removed from the car, and the K Frame. In addition some existing components that will no longer be needed can be removed - BBM Switch, Cruise Module

I want to pressure clean the engine bay so it is more accessible and pleasant to work on ready for Saturday.

Saturday a few of the Sydney Lads have indicated they will drop by to assist with the days tasks.

• The T5 and clutch assembly to be removed from the EL engine and attached to the BARRA.
• T5 Oil Change
• The new K Frame installed - with steering rack etc
• Wiring Loom - installed and tested
• Wiring Loom - OBDII wires spliced into E Series ECU Loom and tested
• BARRA Throttle pedal installed, connected and tested
• Install Barra and T5 into wagon

Sunday will then be installing all the ancillary items like the tail shaft, cooling system, power steering, charging and starting systems. SWC will modify a standard E Series Catylic Convertor to suit the engine and exhaust.

And finally it will be time to see if it will start. No reason why it shouldn't, but you never know.

Then it will be test drive time!!!!

Sooo then, anything I have missed.

Cheers
BenJ

That's a big list & I'm sure you will smash through it like a boss!

Cheers

ToranaGuy

I would encourage the welsh plugs replacement while the engine is out. i had a couple of leaks in mine and they were very hard to replace whilst in the car. I asked for them to all be replaced when the engine was out for head work a few years ago. I am stupid and did not do them on the fairmont while the engine was out I will probably regret it when I finally put it all back together.

Why don't you make some wheel trolleys like these
http://www.kitcarmagazine.com/Featured- ... ollies.pdf

Depending on my schedule, I should be able to drop out and lend a hand as well.

Cheers

Brett

Having observed this monstrosity on Saturday I can only come to one conclusion......

f**k GAY.......................

PS..... Be there Friday arvo mate.

Many hands make light work. I'll give you a hand on the Saturday.

I should be able to pop down on possibly the Friday arvo and the Saturday to get in the way and make politically incorrect and offensive jokes.

That's everything you need when doing a job like this!

With the sort of help on board, it shouldn't take too long to become barra powered!

Cheers

ToranaGuy

See what happens when I weld the Exhaust to the Tailshaft

See what happens when I weld the Exhaust to the Tailshaft

See what happens when I weld the Exhaust to the Tailshaft

It will be another fine example of workmanship on display by SWC

Oh, and nice triple post too mate!

Cheers
BenJ

Just making sure you got the message.................. F'n internet

BA DOHC 30.2 - BBM Removed

Bloody hell, I am not looking forward to ever having to remove and replace a BA BBM with the engine still in the car.

Makes the E Series BBM swap a piece of cake. The wider head overhangs the upper bolts adding an extra degree or two of PITA.

A BIG thank you to the persons who invented ratchet spanners and bent spanners. Luckily I have a wide 10mm selection of shapes and lengths of ratchet and ring spanners to make the job bearable even with the engine sitting on the floor.

Also, for those of you like me who are new to E Series, the engine loom is all one piece, including the transmission, individual coil packs, and cam sensors. When you take off the BBM you have to unplug around 20 other items as the loom goes with the BBM.

Anyway, enough talking.

Pics


At first glance a BA BBM looks very similar to the E and A Series version. But there are a few key differences that won't let you interchange them with previous models. The most obvious is the oval port. This shape would allow for a fair bit more air to flow into the 4 valve head.


And what do I find on the bottom of the inlet runners?


It looks to me like a factory casting designed specifically for mounting LPG Injection Nozzles. Which is exactly what I will do.

I was able to acquire a spare set of nozzles from a mate, which will mean I don't have to disassemble the LPG kit on the wagon as early as I thought I would.

My intention is to mount the LPG Injector Manifolds under the BBM, but inverted. As the LPG vapour is pressurised I don't see this as being a problem.

Any thoughts from the brains trust out there?

Oddly enough, when removing the BBM, I found the bottom rear bolt was missing completely, and quite a few of the bolts where not what I would describe as tight.

Lets see what I get done tomorrow after work.

Oh yeah, I have conflicting information regarding the Rear Main Seal. I have advice from a good source, PapaSmurf, that the rear main seal is the same as the E and A series part. Can anyone confirm this for me?

Cheers
BenJ