It's VERY sludged up.  I just got married a couple of months ago, but the wife states that she had the oil changed at Jiffy Lube every 3000 miles.  Ironically, I did change the oil once, 1 month ago, and the old oil was blacker than the oil in my diesel truck!  No, I didn't use synthetic and I'm sure Jiffy Lube didn't either.

I do run synthetic in my other rides, so would you recommend that I switch to say, Mobil 1 synthetic 5w-30 in the 2.7?

Use synthetic even if it's a cheaper brand 5w30

Well, this 2.5 sure seemed to have suffered from the curse of Jiffy Lube.  I have never, nor do I plan to, take any vehicle to any of those "shops".

The only work I don't do myself is if the vehicle is still under warranty and something expensive needs fixing.

I'll be running synthetic in the 2.7 for sure, thanks.

I must say that I was suprised how much room there is around the v6 in the GV engine bay.

If all goes according to plan, the 2.7 will be up and running this weekend.

The 2.7 is in and mechanically everything is 100% done.



Hirez Version

Notice that the engine harness is laying on the windshield.  Eletrically, a lot of work has been completed, but there is still plenty left to do.  The 2002 harness was for a 2x4, so a couple of 4x4 related connectors were missing.  The 4WD switch (C18 ) was added and wired to ECM connector C-51-3-7 and 4WD low switch (C19) wired to ECM connector C51-1-26.  Both connectors share a common ground with several other connectors, so I was able to splice those into the noise supressor in the harness prior to leaving the engine bay onto a wire that eventually makes it way to chassis connector C52-10.  

Additionally, the vehicle speed sensor (C20) had to be extended due to the lenght added by the transfer case.  Also, the post cat O2 sensors were different, so all those connectors were moved over from my 2000 harness.

The 2000 chassis has a 6 pin connector (C59) behind the glovebox that is not present on the 2002.  So I had to cut this connector from the 2000 harness and splice it into the 2002 one.

The biggest challenge will be moving all the pins around on E61 to match the new ECM.  A total of 22 pins will need to be moved.

Here is a shot of the wiring diagrams that I was using to note all the changes between the 2000 and 2002 wiring:



Hirez Version

And here are spreadsheets noting the changes on connectors C52, C59 and E61:







The 2000 uses an A/C amplifier, where the 2002 apparently have those functions built into the PCM.  So I still need to figure out what to do with those wires.  And the 4WD light, although that is minor.

I also need to get the MAF for the 2.7 as it is apparently located in the tube immediately following the air filter housing unlike my 2.5 which had it on the engine just ahead of the throttle body.

Other changes include the tank pressure control valve being moved from the inside fender to within the intake manifold from what I can tell, so I need to bypass the one on the fender and run the vacumm line directly to the manifold.  I'll need to reduce the fitting on the manifold since it is much larger than the one on my 2.5.

The evap canister air valve wires were moved to the 2.7 harness compared to my 2.5 and must be located next to the transmission since the 2002 harness had a plug for it.  So this will need to be rewired as well.

Mechanically this was an easy swap since the engines are physically the same, but getting the 2002 PCM to properly operate all the other stuff on a 2000 is proving to be quite challenging to say the least!

I'm off chasing down to the guy that sold me the 2.7 to see if he has the MAF, its connector and the air-tube...

Hey man looking great can not wait to see that thing rip.

Thanks JDM.  Believe me when I say I too look forward to going for a spin.  20% extra power should be quite noticable!

Bummer is that the guy I got the engine from is out of town until the end of the week.  Just for grins, I priced the missing parts from suzukicarparts.com, and came up w/ the following:

Air flow sensor (13800-52D00) $718.73
Outlet hose (13881-52D00) $43.58
Resonater #2 (13761-52D10) $18.54

Those are just crazy prices!  I also need the connector that plugs into the MAF since the 2.5 is a 4 pin (only using 3 of them) and the 2.7 is a 3 pin.  I sure hope the guy is going to come through with those pieces, otherwise I'm pretty screwed as I'm not going to pay anywhere near $700 for a freaking MAF!

But I take the prices on that web site with a grain of salt, I mean, they want $560 for the alternator!

Edit:

I spoke to the local salvage yard, and they will sell me the 3 pieces I'm missing for $200 in case the 2.7 seller doesn't have them anymore.  Still more than I'd like, but probably worth it if I can't get them cheaper elsewhere.

Gee Stunt, I just hope I’m allowed to RIDE in this car (let alone DRIVE it) after this incredible engine resurrection/reconstruction!  Thanks for all your hard work on my car! You are a star! We’ll sort out the missing air flow sensor. Meanwhile, after watching “Pimp my Rideâ€? on MTV the other day, I was wondering if you could install:

-A new gold grill
-24 karat gold rims (spinners)
-Curb feelers
-Big truck air horn
-Pink Alligator skin seats with initials T.L.C stitched into the upholstery (and steering wheel).
-Boomerang antenna to watch TV
-3 Xbox game consoles hooked up together with wireless adapters and wireless controllers, able to have up to 12 players
-Smoothie machine
-Clothes dryer
-School bus sign on the side that pops out that says "CHILL"
-Hardwood floors
-Make up kit in center console
-Surveillance camera in the head liner wired to a 15" flip down monitor
-Additional 15" flip down monitor (next to the other one)
-ATM Machine
-Electric Fireplace in the back
-Green neon lights on the inside
-Orange neon lights on the bottom
-12" Fusion woofers with neon rings in the trunk
-4 Fusion amps in the trunk
-A side panel that reads: "Caught Cha looking"

Just kidding, of course!  

However, I would like to ‘publicly’ proclaim how wonderful I think you are! After nearly two weeks of tireless (no pun intended) devotion to this monumental task, your unwavering tenacity and cyborg-like technical skills are the envy of NASA! You’re simply amazing and I love you for it!

stuntwife,

Please take care of your man, because he sure seems to be taking care of you!  

Happy V-Day!

Cwkick

No worries Cwkick,

If I had a mountaintop upon which to shout my undying love and devotion for my husband I would shout it, but since I don’t really have access to a proper mountaintop (per se) this Suzuki forum will do nicely. Please pardon my slightly off topic post, but it is as you point out, Valentine’s Day.

To my Husband:  My Proclamation of love

If another word was never written
If another sound was never spoken
If another daybreak should never arrive
On the heels of a moonlit night

If another breath should never pass
If another moment should never be
If another space and world beyond
Should claim my soul while I slumber

Then let these final words I write
And this final sound I whisper
Be the greatest proclamation
The world has ever known

Of a love so strong and true
And sweet with graceful, timeless wonder
A love that burns to this day
Like the fire of a billion suns

Let this final proclamation ring
For now and all posterity:

You are my love, my life,
My hopes, my dreams,
My all...my love,
As true today as ever...

Happy Valentines Day!  

So sweet!

Careful newlyweds: You should be spending more time in the bedroom than in the garage or writing a bunch of shit on bulletin boards. And there can be no more little white lies now that you're married.   :-/

The 2.7 is in and mechanically everything is 100% done.



Hirez Version

Notice that the engine harness is laying on the windshield.  Eletrically, a lot of work has been completed, but there is still plenty left to do.  The 2002 harness was for a 2x4, so a couple of 4x4 related connectors were missing.  The 4WD switch (C18 ) was added and wired to ECM connector C-51-3-7 and 4WD low switch (C19) wired to ECM connector C51-1-26.  Both connectors share a common ground with several other connectors, so I was able to splice those into the noise supressor in the harness prior to leaving the engine bay onto a wire that eventually makes it way to chassis connector C52-10.  

Additionally, the vehicle speed sensor (C20) had to be extended due to the lenght added by the transfer case.  Also, the post cat O2 sensors were different, so all those connectors were moved over from my 2000 harness.

The 2000 chassis has a 6 pin connector (C59) behind the glovebox that is not present on the 2002.  So I had to cut this connector from the 2000 harness and splice it into the 2002 one.

The biggest challenge will be moving all the pins around on E61 to match the new ECM.  A total of 22 pins will need to be moved.

Here is a shot of the wiring diagrams that I was using to note all the changes between the 2000 and 2002 wiring:



Hirez Version

And here are spreadsheets noting the changes on connectors C52, C59 and E61:







The 2000 uses an A/C amplifier, where the 2002 apparently have those functions built into the PCM.  So I still need to figure out what to do with those wires.  And the 4WD light, although that is minor.

I also need to get the MAF for the 2.7 as it is apparently located in the tube immediately following the air filter housing unlike my 2.5 which had it on the engine just ahead of the throttle body.

Other changes include the tank pressure control valve being moved from the inside fender to within the intake manifold from what I can tell, so I need to bypass the one on the fender and run the vacumm line directly to the manifold.  I'll need to reduce the fitting on the manifold since it is much larger than the one on my 2.5.

The evap canister air valve wires were moved to the 2.7 harness compared to my 2.5 and must be located next to the transmission since the 2002 harness had a plug for it.  So this will need to be rewired as well.

Mechanically this was an easy swap since the engines are physically the same, but getting the 2002 PCM to properly operate all the other stuff on a 2000 is proving to be quite challenging to say the least!

I'm off chasing down to the guy that sold me the 2.7 to see if he has the MAF, its connector and the air-tube...

Now you understand what i was telling you about the wiring being different?? The swap is easy,but the wiring can be a challenge if your doing it for the first time.
Can wait to here how you like it !!!

Careful newlyweds: You should be spending more time in the bedroom than in the garage or writing a bunch of shit on bulletin boards. And there can be no more little white lies now that you're married.   :-/

Who says? What if they like being in the garage? What if they like.. um hanky panky in the garage?  

[austin powers voice]And who names themselves moderator? Seriously?[/austin powers voice]



Thanks stunt and stunt's wife.. this has been a great thread! Keep us all updated on your progress!

Awesome stuff Even the   . You'll got it good Keep it up

Zig

Bump

Well did you getter done?