PT Cruiser V-6 Conversion!

[2002Gold]

quicksilverdon, I just found this article concerning automotive emissions in Hawaii. At this point in time, we don't have any automotive emissions testing in the State Of Hawaii. Here's the article that explains why!

When first-time visitors arriving in Hawaii by air begin their final decent toward the Kailua-Kona airport on the Big Island, they are usually struck by two things. First, the rock graffiti (white rocks arranged in words and phrases on black lava) gets a few marvels. It is truly a neat surprise from the air.

Second, tourists might be stunned by what appears (on windless days) to be air pollution equal to Los Angeles or Houston. However, it's not what you think: Curiously, it's volcanic smog, or "vog."

An island that is home to an active volcano that continually spews subterranean gases sometimes accumulates the murky haze. Although trade winds generally keep the vog hanging over the western cost of the Big Island, it can sometimes show up in other parts of the state, like Maui or even Oahu. the stuff occurs when the volcanic gases come into contact and react with sunlight.

Although the vog, like smog, can trigger health problems such as asthma, the Hawaiian version of air pollution is a naturally occurring substance. Therefore, there's no point in blaming cars for its presence.

Thus, at this point in time there are no set emissions standards for vehicles in Hawaii. At the same time, the state is on the frontlines of the electric vehicle movement and has a praiseworthy number of hybrids on the streets.

Other than the vog, Hawaii's breezy location in the middle of the Pacific and the rather small population keeps the air quality in relatively good shape. As a matter of fact, Honolulu consistently ranks as one of the cities with the least ozone air pollution.

Plus, with the massive number of scooters and mopeds about, residents tend to be on the low-emissions side in many cases anyway. And gas prices are so elevated that many people simply buy efficient (and by correlation, low-emissions) vehicles out of necessity.

So for now, you need to only get a safety inspection to register your car―you can skip the emissions test.

Thanks again for your support. Aloha, Tommy.

[2002Gold]

I know you guys like to see pictures, so do I. The 1st picture is an exterior shot of the transmission tunnel completed. Here you can see more clearly where I cut off the main crossmember in the green circles. The 2nd picture is of the interior after I re-installed the carpet, floor shift console and floor shifter. Don't look like theres a GM trans under there, does it? Still looks like the stock floor. Shortly after that is when I modified the floor shift console and floor shifter. The gas pedal was relocated to the left a little, and the brake pedal was re-positioned to the left as well. Thank you, Tommy.

[Mean Green]

Rather small population? You must not be talking about Oahu. I grew up there, left in '74 (I was 23 yrs old) and came back in Sept. for the first time in 35 yrs. I was sickened by how crowded it now is. I'd like to move to the big island, though.

[2002Gold]

Originally Posted by Mean Green

Rather small population? You must not be talking about Oahu. I grew up there, left in '74 (I was 23 yrs old) and came back in Sept. for the first time in 35 yrs. I was sickened by how crowded it now is. I'd like to move to the big island, though.

Yes, I live on Oahu in Waianae on the Leeward Coast. Yeah, if you like your freedom, the Big Island is the place to live. Take care Mean Green. Aloha, Tommy.

[quicksilverdon]

Did you have to start over with another PT, or re-work what you did w/the Chevy V-6?
Either way, a lot of work!

[2002Gold]

quicksilverdon, I removed the Chevy 3.8 V-6 engine shown below in the 1st picture, and 4L60E transmission. I also removed the Chevy PCM at the top left of the picture and engine harness that gave me tons of electrical problems. Then when I went to fit up the Buick 3.8 V-6 and 200R4 transmission, I found out that I had to lower the engine a little more to clear the tunnel that I fabricated for the Chevy engine and trans. The diameter of the 200R4 trans is slightly wider than the 4L60E trans that I was using with the Chevy 3.8 V-6engine. That's why I had to cut, remove and modify the main crossmember below the firewall. I then had to fabricate another crossmember for the front engine mounts and rack and pinion assembly. Once I get the main crossmember all welded in solid, I can then prep the engine compartment to do the final install of the Buick 3.8 V-6 engine and 200R4 trans shown below in the 2nd picture. The hardest part this time was to fabricate the new front engine crossmember, because the rack and pinion assembly bolts to it as well. So, everything had to line up perfectly, no room for errors. I also had to keep a 3 degree engine angle so that the carburetor's mounting surface would be as level as possible for the 4 barrel Holley. So far, so good! I'll try to keep posting pictures as I progress with the project. Thank you, Tommy.

[AlTheKiller]

wow thats some great work. any idea on how many man hours its taken?

[2002Gold]

I have not kept a note on the man hours spent on this project. I can tell you that the PT Cruiser has been on jack stands from April of 2004. Most of that time was spent on the Chevy 3.8 V-6 application which had numerous electrical problems. I troubleshooted the electrical system for 2 years. Due to that, the engine then started knocking. It sounded like a main bearing knock. I believe that because the electrical system was so screwed up, the computer feed more gas than necessary through the system and eventually the gas got into the crankcase and did the damage. I was changing the engine oil and oil filter every two weeks trying to avoid something like that from happening, however it happened anyway. For this Buick application, I would say I have been working on it off and on for about a year. I work on it only when I feel good. I'm 61 now and it gets harder as time moves on. Those of you who are at the same age know what I'm talking about. If I were in my 20's, the project would have been completed long ago. I'm doing most of the work by myself. The new gas tank is being built by a shop. I did not want to deal with that! Projects like this take time. When you do something that has never been done before, it takes up allot of time. There are no kits out there that you can use for the structual work. Everything has to be designed and fabricated by yourself, using your own thoughts and skills. Today, 5 years after I started the project, there are much more kits available for the electrical and mechanical side, but still no kits for the structual side. There are no bolt on crossmembers for the engine and trans, or for the main cross member that I'm aware of for this V-6 conversion. For the engine compartment, the hardest part is done. It is just a matter of getting all the new wiring in, fuel line, exhaust system, cooling system, brake lines routed and hooked up. Then the next challenge will be the installation of the rear end housing. As mentioned previously, I will be using a 2002 Jeep Wrangler rear suspension which will also be modified to use leaf springs. It currently has a coil over suspension system. Here's a picture of what my PT looks like now. I have a few plans for some changes on the exterior as well. Let's see what happens! Thank you, Tommy.

[grungerockjeeper]

Is that gonna get the Grand National turbo treatment? Thatd be HAWT!

[2002Gold]

Originally Posted by grungerockjeeper

Is that gonna get the Grand National turbo treatment? Thatd be HAWT!

Yes, we shall see how things turn out. Once I get the engine running nicely, the sky is the limit, who knows! Thanks for looking, Tommy.