Betsy, my 67 s2a build.

**67hardtop** · 13th December 2018, 10:15 AM

Yeah the spray can stuffed up and shot a big load just at the wrong time

. Bugger. I dont care coz its at the back.
Yes Paul, a lifting lug coz original one was missing and need to lift it in with something

. New fuel pump coz diesel and petrol use different pressures and diesel pump kits were not available. Plus it looks good

.
John, im not sure what those senders or switches are for, but the small one is for the oil light, the other 2 ive been told, are something to do with the reverse lights. The engine is out of a s3 1976 109. Aparently the reverse lights dont work unless the engine is running, similar to perenties ive been told. I dont have a s3 diesel wiring diagram to check it with, so i cant be sure, tho my perentie has the same switches on it, (not connected) coz my reverse lights dont work anyway

.

Thanks for the interest guys

. It helps to get me motivated

.

Cheers Rod

**67hardtop** · 13th May 2019, 07:01 PM

Been a long time. Today i cleaned up my work bench a bit. Put new cardboard down on top. Then i located and cleaned the diesel flywheel housing and bolts. Shock horror i actually did some work on Betsy. Was unable to lift engine onto the bench coz i dont have an engine crane atm but will try get one tomorrow. That motor is very heavy. Then ill fit the flywheel housing and flywheel. Then ill assess the clutch and refit it if its good. If not then ill fit a new clutch plate. I have a new spigot bush soaking in oil for a few months. Then ill just drop it down for storing while i dig into the gearbox n transfer. Then its gonna be the overdrive. Nightmare on the way. Its really noisy but works ok. Guess ill just wait n see.

Cheers Rod

**bemm52** · 13th May 2019, 07:31 PM

Post heaps of pictures when you look into your gearbox/transfer as I've got to do the same and have no idea where to start

Cheers Paul

**67hardtop** · 13th May 2019, 08:08 PM

Originally Posted by bemm52

Post heaps of pictures when you look into your gearbox/transfer as I've got to do the same and have no idea where to start

Cheers Paul

Niether do i Paul...hahaha. I'll be reading the manual as i'm pulling it apart....

**gromit** · 14th May 2019, 05:39 AM

Originally Posted by bemm52

Post heaps of pictures when you look into your gearbox/transfer as I've got to do the same and have no idea where to start

Cheers Paul

Have a look in my thread on Wallit (Series III fitted with Isuzu C240).

Isuzu C240 powered Series 3

I copied & laminated the pages from a Haynes manual and worked from that.

Colin

**Cap** · 14th May 2019, 08:11 AM

And theres a couple of vids which helped me to understand them that are quite good, heres the 1st one which was also posted on another thread before.

**67hardtop** · 14th May 2019, 08:00 PM

So i managed to get the engine crane this afternoon. Ended up fixing a holden Viva while i was there. LH R handbrake had locked on and new owner, bought it yesterday, drove it in with wheel locked. Tyre ruined. Nearly new now with a huge flat spot worn thru past first layer of steel belt. Had she reversed it would have freed itself. I suppose we wouldnt have found it then.

So back to Betsy, i lifted the engine onto the bench and supported the front. I sealed up the flywheel housing onto the block. Fitted a new O ring seal as well. Torqued up the bolts. Cleaned up the flywheel. Bloody heavy those diesel flywheels. Only just got thru the housing too. Fitted a new spigot bush. Locktited and torqued up the bolts. Now i have to sort out the clutch. The original diesel clutch is s3. Its getting a s2a box put on it so the pressure plates are different. Next time i get to it im gonna check the diameters etc. Hope they are the same. Then ill have to check if the s2a petrol engine clamping force is is the same. Heres hoping....cant afford a new one just yet.....hmmm.

Cheers Rod

**Cap** · 15th May 2019, 08:16 AM

Clutch pressure plate is NOT the same for the early throw out bearing and the later fork style (series 3). I went through the same process with mine, early 2a box with a S3 engine.

Ended up buying the pressure plate with the spacer where the throw out bearing contacts as below

Also, my old petrol engine only had the 9" clutch (with two dowels) so luckily the diesel clutch was still in good cond so I re-used. Heres my vid on the job showing the pressure plate

Cheers,

**1950landy** · 15th May 2019, 01:26 PM

The easy way to remove the spiggot is to fill the hole up with grease then use the line up tool to hydraulic the bush out. Give the lone up tool a hit with a hammer & because the greasecwon't compress it will pushbthe bush out. Saves a lot of time with a hacksaw blade & running the risk of damaging the hole in thed crank shaft.

**67hardtop** · 15th May 2019, 07:02 PM

The old spigot bush was very loose. I pulled it out with my fingers. Looked like it had been spinning for a while. New spigot bush had been soaking in oil for about, oohhhhh 8 months. Totally forgot about it. So i just knocked it in flush with a big socket and little hammer. All good. I found out the s2a pressure plate fits on the s3 diesel flywheel. Clutch plate is the same size as the diesel one. Might buy a new clutch plate just coz i can. The one i have is still good prob 50% worn so while its apart ill just do it. Still need to see if i can get the clamping force checked.

On a side note. The Viva i spoke about yesterday was a bigger job than we first thought. The timing belt was noisy. Had been replaced in Jan '19 by some other workshop. Upon removal I found the belt had been fitted backwards...ie the direction arrows were pointing the wrong way. It was thump thump thumping as it was running. So i fitted a new belt and rollers, as they hadnt been changed when the belt was, but they had fitted a new water pump. The rollers and tensioner were noisy as well. Seals had been replaced before as well. Beats me why they only did half a job. Put it all together. Started and ran good no noises. When i fitted the new drive belt, coz the old one was cracked to hell, again only half a job by previous shop, I found the alternator was loose. Two of the 3 bolts that hold it on were missing. Beats me how some ppl stay in business. I fitted 2 other bolts and secured it. The bottom bolt was still tight. Anyway got it all together. Two new tyres as well. Drove it. Gutless. Found the engine light had been removed. Fitted a new light globe n socket. Had trans codes P0703 P0700. Neutral switch no good. Thats why it wasnt cranking at times. New switch is insanely priced. Managed to clear the code and retensioned the contacts so it was no longer in limp mode. When the customer has more money shes coming back to get it fixed. She only bought it on Monday and privatly too. No warranty. Bill was $1200 for work done yesterday and today. I feel sorry for her but thats the way it is. What a lot of workshops dont realise is the reason the timing belts get changed every 60k on the holden astra, vectra 4cyl, viva, barina etc, is, the rollers fail, not the belt.

Anyway enuff said.

Cheers Rod

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