1992 Caprice Station Wagon 305 V8 vs 6.2 Liter Diesel

[oil pan 4]

Replace the front and rear main seals while its out.
I would recomend also resealing the front cover and timing plate and resealing the oil pan.

[vacationtime247]

Ordered some parts today. Got a B & M transpak shift kit for the 700R4, a TCI TCC 4th gear Torque converter manual lockup kit, 2 large coolers for the engine and trans, a 4th gear 3/4 shift valve so it won't downshift to 3rd past 1/2 throttle. Going to order the accelerator cable for a 83 diesel p/u and modify it for the Caprice. Have a spare fuel filter canister for a 7.3 L idi Ford that I'll modify in too. Instead of getting a new TV cable I'll set the old one then use a screw in crimp fastener. Going to take off the exhaust so the bottom bolts can be rethreaded at a muffler shop. Waiting on parts to arrive.
VT247

[vacationtime247]

Took a nap late afternoon and now I'm still up. No work tomorrow so that's good. Got some tranny parts in and putting them in now. TCI Torque converter lockup kit, B&M transpack for firm shifts, 3/4 upshift valve, and a tranny and oil cooler. Will post up pics soon. Inside now getting my drill bit tightening tool.
VT247

[vacationtime247]

Got the transpak, 3/4 upshift valve and the TCI torque converter TCC lockup kit installed. Got the new throttle cable put on. Going to bolt together the engine and trans and get it set down in the car soon. Took the manifolds to the muffler shop and had them take out the old studs and rethread. Put the manifolds back on yesterday. Put in new glow plugs. Still putting all the pieces of the puzzle together. Coming along nicely.
VT247

[dupree]

loving this, keep up the good work

[vacationtime247]

What a nightmare of a job this has turned out to be. Got the engine in with A LOT of persuasion. Going to have to remove the anti-lock brake module so I can mount the power steering pump. Need a hat to put on the intake for the air cleaner, it won't work with the original air filter. Mount up the oil and trans filter to the radiator. Mount an electric fan to the radiator too. Run the lines for the torque converter lockup. Mount and run the accessory gauges. Re-connect everything. I'll get some pics up of the progress. It'll get done, but feels like one step forward and two steps back. Soooo much stuff to get done to this car. Still finding more that needs fabed up. We'll see how it turns out. Had to disconnect the windshield wiper motor to get it to go in. Had to take off the power steering from the engine to get it in. Still have to tweak the engine mounts to get the bolts through. One sides aligned, the other is just off by a 1/2 inch. This AFTER I torched off the tabs on top to get it in. Grrr.... Hope this is worth it. Feels like a never ending mission!
VT247

[slowmover]

Coulda told you this, but . . . . . in for a dime, in for a dollar!! Might feel sorry for ya if this was a year plus into the project, but you've moved right along and I'd imagine you're up to the task.

I'm real curious as to how the steering linkage will work out, and what the weight scale will show before & after.

.

[vacationtime247]

Yea, it'll get done. But didn't expect to have to remove the ABS to get the PS on. Hope to prolong the tranny life with the B&M transpak, a manual torque converter lockup and a large cooler. The air cleaner will need to be modified too. From the looks of it, the car doesn't seem to sit any lower with the heavier diesel in there. Perhaps I'll run it across the local landfills scale to get an idea of it's current weight. Once it can pull it's own weight that is. lol
VT247

Originally Posted by slowmover

Coulda told you this, but . . . . . in for a dime, in for a dollar!! Might feel sorry for ya if this was a year plus into the project, but you've moved right along and I'd imagine you're up to the task.

I'm real curious as to how the steering linkage will work out, and what the weight scale will show before & after.

.

[Rusty Marina]

Interesting project, just scribing to the thread.
Be interesting to see the numbers.

[vacationtime247]

Pics! Here's what's going on now. Garage is a mess, tools, parts everywhere, tons of things left to do. Just want it to run and move under it's own power. So, on with the pics and what's going on in them.
VT247

Here's how the garage looks now, cutting torches out, need to put them up. Air compressor lines wound around the car. Need to put the tire on the passenger side and push the car out. Then clean up. Push it back in and get it all bolted together and wired in. Motor mount bolt holes giving me fits. Need to figure out how to get them both on. Might trim up the engine mounts, already cut off the tabs on the frame mounts, only helped a little.


As you can see here, the engine is in. Trans mount needs put on in on the back, but that won't be until the motor mounts bolts go through.



Problem #1. The antilock brake system is right where the power steering pump needs to be. I'll have to re-route the brake lines to make room. But, until I trace the lines and get that plumbed in, I'll leave the power steering off. Yea, for FE reason a PS delete would be ideal, but this car will need to make it up and down Trail Ridge Road, CO. Beefier brakes and new suspension will be later.





Sits in there with plenty of room to work on it. However, I'll need a hat to relocate the air filter going to the intake. The firewall / cowl won't allow the stock air filter to fit. Had to remove the cruise control vacuum unit had to be removed so the hood will close.





The hood does close. Think it hits the canister for the blow by routed to the intake. Seems to be flush. Might fire up the torches again and bend the bracket down some as long as I have room for the hoses.



Got an oil, temp and volt gauge set I'm planning on installing. But, where to mount it?



Had to remove the windshield wiper motor bolts to get the engine slid in. Also had to remove one heater core quick disconnect line for it to drop in. Luckily though, all that needs done is for them to be hooked back up.



Side view of the 6.2 liter Diesel engine in the Caprice.



Cruise control can come out. Won't be using this one. Didn't work when I got the car.



No problems with the steering linkage! Woo Ra!



No problem with where the exhaust exits on either side!





The canister that I believe is hitting the hood. Can't tell with the hood closed, but I'd rather it didn't rub or hit.