Rosie - My 1992 Gl Automatic 2016 Project

[FestYboy]

Remember that rockauto is a supplier, not a manufacturer. They can't be held liable for faulty manufacturer construction.

[1990new]

Maybe I'm getting old and cranky... or maybe my comment about "scathing email" was misunderstood.
In the email I simply stated that I was not satisfied with their response to the issue I presented and asked them
to please look into the problem and correct the listing. Yes.. I actually said please and thank you.
This morning I received a very nice email, apparently from the manager of the customer service rep I was dealing with.
He admitted that the listing showing the vacuum modulator would fit the Festiva was a mistake and said it would be removed.
(As of right now it still has not been removed however.)
He issued me a credit for the cost of the part plus shipping and said I did not have to return the part (anyone need a vacuum modulator for an early 70's Ford? it's yours for shipping).
He also asked me to send measurements and pictures of the transmission mount I received from them compared to my original mount.

So yes, I will continue to order parts from RockAuto and recommend them to others. And maybe I will have prevented other Festiva owners from getting the wrong part from RockAuto.
Thus endeth the RockAuto Saga.

[1990new]

Today was hot and humid so I didn't work outside too long on Rosie.
I did get the engine dropped in the bay, bolted the right motor mount to the body, attached the front trans mount to the crossmember
and loosely connected the front cross member to the body.

It's been a while since I changed and engine..so will someone please remind me how to get the rear mount attached to the crossmember and then to the body. I'm having difficulty getting things lined up.

The service manual say to attach the cross member first and then mounts to the cross member, but I vaguely remember having a problem getting the bolts three bolts to line up doing it that way.

I added a few more pictures to the library. Some showing the vacuum modulator installation and the engine dropped into the bay. I will upload more pictures of the engine install tomorrow.

[1990new]

Today I finished installing the engine and transmission. The transmission mounts went in fine once I put the cross member in first as specified in the manual.
Got everything hooked up, added, oil, antifreeze and distilled water, and transmission fluid.
When I turned it over I found out that I had two injectors leaking gasoline badly at the fuel rail.
I had used a better looking fuel rail with injectors that I had sitting on the shelf and that was a mistake.
Now I'll have to pull the rail and get new seals before I can start the engine.
Meanwhile I will finish connecting the axles and the front suspension.
I'll disable the fuel pump and check the compression tomorrow.
Stay tuned...

[1990new]

Axles, steering and suspension all connected.
Checked the compression today and it is close to 170 on all four with a cold engine and a closed throttle.
Have to wait until I get a good not leaking fuel rail installed before I can start her up.

[1990new]

The discoloration on one of the injectors on the Rosie's original fuel rail looks like it had a slow leak too.
So I ordered 8 injector seal kits from RockAuto to get both fuel rails back in good condition.
It could be next Tuesday before they get here so I will not post an update until I get a good fuel rail back in.
I did get a new 5 lb fire extinguisher today so it will be standing by when I start Rosie up after installing the fuel rail.

[1990new]

Today I removed the pistons from Rosie's old block, took pictures and uploaded them to the Rosie project library.
The number 1 piston was the only one on which all the rings were still in position. The top ring was broken on the other three
and the oil rings were broken on a couple more. So it's no wonder she smoked so bad.
The number 4 piston where the edge was broken was the worst, as you can see in the picture.
The inserts showed very little wear and the cylinder walls showed no scaring.
The crank turns super smooth so the main bearing must be in good shape too.
I'll take my time to round up the parts for a rebuild of this block for future needs.

http://s1222.photobucket.com/user/19...osie%20Project

[1990new]

I posted this in the help forums as "Fuel Injector firing" so please respond there to help.

Got the injector seals in the mail today and the rail is back on with no leaks but....no start yet.
Leading up to this point.
Installed the timing belt:
Lined up the 12 and 3 oclock marks on the cam pulley and the lower mark dead on in the sprocket valley and installed the belt.
Turned the engine over a few time and belt line up appears to be good.
Confirmed cylinder 1 is at TDC when the marks line up.
Confirmed that the rotor button is at the number 1 plug wire when cylinder 1 is TDC
With number 1 plug out I confirmed that I get a spark when engine is turned over.

Turned over several time but the engine has not fired once.

I know I'm getting fuel at the rail but how can I check for fuel in the combustion chamber without remove the fuel rail again?

[bravekozak]

Pull a spark plug and see if it's wet with gas. Take a quick sniff. Good luck.
Make sure it has some advance.

[1990new]

Pull a spark plug and see if it's wet with gas. Take a quick sniff. Good luck.
Make sure it has some advance.

I pulled plugs 1 and 4 and they are not wet and have no gas smell, So it does appear that I'm getting no fuel into the cylinders.

[FestYboy]

Yellow/Green wire on the injectors is power, should be there with key on. PCM controls the ground to pairs (batch fire). You can back probe the grounds with an LED test light.

[1990new]

SHE RUNS
Noid lights confirmed computer is sending fire signals to injectors.
After I put the original injectors and rail back on Rosie she runs. Not good to use injectors that have been sitting on the shelf for years without having them cleaned first.

Have a problem with skipping on cylinders 3 and 4. Tested by removing plug wires one at a time and the two at a time to target the misfiring ones.
Plugs and wires to 3 and 4 are good though so I must have messed up the 3 and 4 original injectors trying to clean them.
Will get that problem solved tomorrow before I drive her. I'm just real happy that the new engine is finally running.

[1990new]

Rosie sat for about 4 hours and I started her back up about an hour ago and now there is no skipping and she is running good.
Those two injectors somehow started working after sitting a while with the fuel rail charged.

One more problem that I didn't mention earlier. I have a very loud mystery noise that almost sounds like the starter gear didn't retract after starting. I'll tackle that problem tomorrow.

I checked all around the oil pump, bottom pan, valve cover etc and so far no oil leaks.

After starting and running and shifting through the gears, the transmission fluid level that appeared overfilled did level off right at the full mark.

[bravekozak]

No James Bond smoke screen?

[1990new]

No James Bond smoke screen?

Looks like my 007 adventures in Rosie are over. No smoke and the engine is running like new.. which it should be.

Now to find a solution to the mystery noise problem.
The noise mystery is solved but now I need a solution to the problem.
I removed the starter this morning and the noise is definitely the bendix gear getting stuck in the flex plate.

You can see where the constant high speed turning of the gear on the pinion has turned it blue.

I took the starter to autozone a little while ago and it passed all the tests that their machine does.

I posted this in the help forum so please comment on solutions there so the forums searches work like they should.