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88 2.5 rebuild by Zeak
Started on: 10-26-2014 03:58 PM
Replies: 60 (2123 views)
Last post by: edfiero on 11-09-2015 10:58 AM
Zeak
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Report this Post12-18-2014 10:13 AM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

 
quote
Originally posted by olejoedad:

That is the Battery Junction Terminal.
The same style is used on several GM models from the 80's and 90's.


Thanks!
Got some more items installed. I made sure to seal the bolts that hold the DIS brick to the block.
You can still somewhat see the new shield that I made behind the packs (Thanks again ogre!)

This pic is of the bottom of the intake and the back of the alt.


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Zeak
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Report this Post12-20-2014 06:34 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

 
quote
Originally posted by olejoedad:

That is the Battery Junction Terminal.
The same style is used on several GM models from the 80's and 90's.


Ok, So just wanted to make sure my ducks are in a row.
The battery junction has a wire directly from the battery to it, so it's hot at all times. Right?

[This message has been edited by Zeak (edited 12-20-2014).]

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olejoedad
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Report this Post12-21-2014 01:12 AM Click Here to See the Profile for olejoedadClick Here to Email olejoedadSend a Private Message to olejoedadEdit/Delete MessageReply w/QuoteDirect Link to This Post

Yes. The alternator, battery and chassis power feeds all attach to the BJT.

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Report this Post12-21-2014 01:15 AM Click Here to See the Profile for olejoedadClick Here to Email olejoedadSend a Private Message to olejoedadEdit/Delete MessageReply w/QuoteDirect Link to This Post

Sorry. Double post.

[This message has been edited by olejoedad (edited 12-21-2014).]

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Zeak
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Report this Post12-21-2014 03:40 AM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Ok, Thanks!
It would seem in my haste to remove the engine and start cleaning, I forgot to document that part....

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Zeak
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Report this Post12-25-2014 01:37 AM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

So Marry Christmas everyone.
Was double checking my rocker arm bolts before I bolt down the valve cover and fill the oil.
I noticed that even at 24 ft/lbs. The rocker arms and push rods on some valves are still very loose.
Wanted to ask you guys and gals if the hydro lifters would take up the slack after I build oil
presser or if I need to look into the bolt shim trick....

Also tryed the David freiburger (from motortrend) spark plug wire separator.

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Zeak
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Report this Post12-25-2014 12:41 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Oppps. Nevermind. I was using the wrong key word for my search.
lifter tic

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Zeak
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Report this Post12-26-2014 10:33 AM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Well crud. Was not able to get shims yet, but as I removed a rocker stud, so I could get the proper size.
I noticed that this bolt has normal wear on one side from the bole shaped washer, But it also had scaring on the other from the rocker making direct contact to it. It dose not look like much, but I don't want it to get any worse and brake the bolt or something.
If I'm not wrong, The shims would only increase the amount of contact. Right?
Should I still do the shims and just file the rockers or is something else wrong here? All 8 bolts have different amounts of the same markings.
Back side, normal wear.

Front side scaring

Doodle to show where it's hitting When the valve is fully open.

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Zeak
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Report this Post12-30-2014 01:19 AM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Got the rockers sorted out with some shims and a little grinding with my dremel.
Primed the oil system by rigging an old garden sprayer to the oil pressure port.
Cranked her over until the oil gauge hit 40.
Got everything else installed and went for a start.
.......
Swapped my spark plug wires from "shooting fire from the throttle body'' to the ''run'' setting and she started right up.
No leaks.
No longer has the diesel engine "tick". (Will see how long that last after brake in)

I could not run her too long as she's still backed into the garage, but I'm happy for now.
I need to find a new throttle cable as mine is frayed near the throttle body and is about to brake.

[This message has been edited by Zeak (edited 12-30-2014).]

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theogre
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Report this Post12-30-2014 10:57 AM Click Here to See the Profile for theogreClick Here to visit theogre's HomePageSend a Private Message to theogreEdit/Delete MessageReply w/QuoteDirect Link to This Post

Too thick "shim" and you can break things. Washers as shim are too thick many times.
Most engine Exhaust valves grow more then intake side. Is more easy to cause problem by shimming exhaust.

Some wear is normal. The ball often rotates to keep wear even. Many aftermarket balls have oil groove too.
Minor Rocker hits the bolt is common.

see http://www.fiero.nl/forum/Forum2/HTML/103494.html

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Zeak
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Report this Post12-30-2014 12:03 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

 
quote
Originally posted by Zeak:

Oppps. Nevermind. I was using the wrong key word for my search.
lifter tic


I linked to the same post before.
To move the rocker to where I wanted it. I used a thick shim under the bolt head at the pivot point and a thin shim at the base of the bolt to compensate. I turned the engine over by hand several times to check for any interference.
I did not want to have the rockers hitting anything, but did not want them to open the valves too much either.

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Zeak
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Report this Post01-01-2015 07:15 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

So today I found that my head gasket was leaking. I've never used new head bolts like these.
The 3 steps for setting them seem to be beyond me....
I pulled the valve cover and cleaned the oil off of everything.
Re-set them and we will see how it goes.
Anything else I could check?
Oil and coolant was spurting out behind the header shield.

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Zeak
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Report this Post01-12-2015 10:45 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

So I'm back home from my trip to Tx.
Got her cleaned up and started. All new sensors.
Now Whenever she gets warm, she starts bogging down and dies.
Also have the leaking valve cover gasket. Tried the high dollar blue one. The cork one. The cork one with a coating of Rtv.
Made sure everything is clean and the valve cover it's self is flat.
I dont know........

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Zeak
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Report this Post01-19-2015 02:09 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Got her running. Just haft to get the trunk back on and watch for any more leaks.
Thanks again for all the help and advice!

Edit: this is her running without the belt tensioner, btw.

[This message has been edited by Zeak (edited 01-19-2015).]

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Zeak
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Report this Post01-20-2015 07:04 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Started her up this afternoon and a really bad knock started.
Never heard this one. It's a light tick at idel and a bad diesel sound with any amount of throttle.
WTH?!?!?

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Zeak
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Report this Post01-21-2015 09:38 AM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Nm. I got to thinking, I started this about 3 months ago.
My gas probably just went bad. ( I did not add any stabilizer)
Going to drop the tank and clean everything up.
Replace the pump, both the line and sock filters.
On the newer stile pumps, Was there ever any follow up on if we
need the pulsator or not?
I know I need to buy the FI hose that's meant to be submerged in fuel, but
not sure on the other part as I've seen people on here keep it and toss it.

[This message has been edited by Zeak (edited 01-21-2015).]

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nosrac
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Report this Post01-22-2015 11:33 AM Click Here to See the Profile for nosracSend a Private Message to nosracEdit/Delete MessageReply w/QuoteDirect Link to This Post

 
quote
Originally posted by Zeak:

Started her up this afternoon and a really bad knock started.
Never heard this one. It's a light tick at idel and a bad diesel sound with any amount of throttle.
WTH?!?!?


Man I hope that isn't a rod knock. My fingers are crossed.

I recently got my 88 "Duke back on the road but instead of a rebuilding the engine I found a 50K engine and it is working out pretty good so far.

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Zeak
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Report this Post01-25-2015 10:28 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

Bad news.
Pulled the spark plugs and turned the crank until each piston was at tdc.
Using a screwdriver, I pushed down on each piston.
Cylinder #2 had the "clunk".
A big one.
I dont know what really happened, but my guess is I've spun the con rod bearing.
As it stands right now. I'm somewhat fed up with the duke.
I still have my 02 pontiac gtp under a tarp in the drive way.
I'm about to the point of just swapping the 3.8sc and auto trans into the fiero.
I'll be done with the isuzu 5 speed. I already hate that thing with a passion.

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Report this Post01-25-2015 10:36 PM Click Here to See the Profile for nosracSend a Private Message to nosracEdit/Delete MessageReply w/QuoteDirect Link to This Post

 
quote
Originally posted by Zeak:

Bad news.
Pulled the spark plugs and turned the crank until each piston was at tdc.
Using a screwdriver, I pushed down on each piston.
Cylinder #2 had the "clunk".
A big one.
I dont know what really happened, but my guess is I've spun the con rod bearing.
As it stands right now. I'm somewhat fed up with the duke.
I still have my 02 pontiac gtp under a tarp in the drive way.
I'm about to the point of just swapping the 3.8sc and auto trans into the fiero.
I'll be done with the isuzu 5 speed. I already hate that thing with a passion.

Sorry to hear the bad news but you won't regret swapping to the 3800. That is my plan in a few months. I wanted to get the Duke back on the road first so I could fix all the little issues and not have a garage queen.
Now that the Duke is back on the road I have a whole lot of little things to fix first but will get to the 3800 swap as soon as I can.

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Zeak
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Report this Post01-28-2015 09:07 PM Click Here to See the Profile for ZeakSend a Private Message to ZeakEdit/Delete MessageReply w/QuoteDirect Link to This Post

My mechanic came and picked her up.
I wont be stating a build thread until I get her back in a month or so.
T-T

[This message has been edited by Zeak (edited 01-28-2015).]

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edfiero
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Report this Post11-09-2015 10:58 AM Click Here to See the Profile for edfieroClick Here to Email edfieroSend a Private Message to edfieroEdit/Delete MessageReply w/QuoteDirect Link to This Post

What happened? Did ya get her back on the road?

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