Top end rebuild problems

[Compufreek]

I am rebuilding my top end on a 95 GP 3100 and have come across some problems. How many connections are there to the coil packs? I have one small one on the passenger side and one large and two small on the driver side. well after getting everything back together I had one plug on either side that were color coded and fit but there is one more plug in that area that there is nothing else noticable that it will plug into, and it won't fit the last connection on the driver side of the coil pack. Is this just an unuased plug? it looks pretty dirty. Is there something supposed to be in the small connection on the driverside of the coil packs? Now I did try turning it on to pressurize the gas lines but the back connection on the fuel rail poured gas out. Is this a bad seal or is something going wrong? I usually hear what sounds like a spraying sound but didn't this time. Any help would be very appriciated!!

[v6h.o.]

what colour is the spare connector??

sometimes there is one spare Red connector from the factory used for p/s systems in some cases.

[Compufreek]

yup it is a red clip, I hope that's the extra one. Is anything supposed to be in the othe connection on the driver side small connector?

[bszopi]

For some odd reason, I keep thinking that there is only 3 connections to the ICM...



And this diagram confirms this...

[v6h.o.]

if its red check you should have Two Red coloured connectors back there.

one for the EVAP Purge Solenoid, and the other will be that spare connector that isnt used.

i dont think you can mix up the purge with the spare one either. they only plug into one or not.

[Compufreek]

ok the solenoid looks to be plugged in and the other red connector is floating. That seems to be fine but the purple and yellow crankshaft position sensor that is missing. Do you know where it will be coming from, could it have fallen behind the engine or something?

[v6h.o.]

yeah the crank signal should be coming up from the rear of the engine, it usually gets attached to the drivers side of the rear head near the fuel rail/coolant pipe bracket that is on the drivers side of the rear head.

look around that area, should be kicking around there

[Compufreek]

ok I got the wire but now I tried to turn it over and the starter just spins the motor...not even a sputter! What did I forget? I really hope I didn't screw this up. Every thing is torqued to spec and I never touch the cam or crank so timing should still be fine.

[bszopi]

It'll be one of 2 things if the engine is just spinning over: fuel or spark. So start there. Make sure you don't have a blown fuse going to the ignition or fuel pump (or even injectors). Check spark at the plug wires. Check to see if the rail is being pressurized or not. Just a few ideas to get you going...

[Compufreek]

Well got her running and it seems to be ok. Think I flooded it. Held the throttle body open and tried to start it and it went. Well there was a little smoke but it settled out. There is a little smoke coming from the engine but it could be because of the paint and a minor coolant leak at the water pump. It also starts up on it's own now but there seems to be a lot of valve chatter as if it was cold from before but lasted a little longer. What do you think?

[v6h.o.]

sometimes you will get alot of noise from the valvetrain after doing an intake,
its just from the lifters needing to get settled again.

one thing that always gives me a spook is this, sometimes when i use my small 3/8 impact gun to run down the rocker arms what happens is it makes the plunger stick in the lifter for some odd reason, holding the valves open? why i dont know?
so then when you go to start the bastard, it turns over like its got no compression at all, just freely turns makes no compression noise at all.... its a sick feeling after youve had an engine apart and this happens, your mind races and thinks what the hell did i screw up, but to solve this, you just need to keep cranking the engine over for an extended period of time. builds enough pressure lets the lifters settle back down and get right she fires right up.
like i said, its odd. but man does it through you for a loop at times..

[Compufreek]

I have been also getting a wierd smell and some smoke. That could be the stuff that has been spilled when taking off the parts and also the paint I used on the valve covers and intake manifold and plenum but it almost smells like burning plastic. I also have to say thank you for all the help I am so freaked having never done it before.

[Compufreek]

Also how long do you figure the chatter will last?

[bszopi]

If you smell plastic burning, make sure all the wire loom is away from the exhaust manifolds. When you start to move all the wiring around, stuff gets repositioned, usually to areas you wish it hadn't. Might want to check all that before it goes too long and you start burning wiring instead of just the loom.

[Compufreek]

yeah the smell has gone away but I will check the looms. What realy worries me is the chatter. I also thought, is it maybe from shaving the heads? I did go down .015