3s surf

[tristanp]

righto
i did a deal and ended up with a surf with no motor and a 3sf motor in the back
i also happened to have a liteace 4x4 van with the 2c diesel ... so i heard stories on the net about the 2c bellhousing being the magic glue for 3s motors and hilux/surf boxes, so away i went
i dragged the van onto its side with the lj50 and unbolted the gearbox


then unbolted the bellhousing.. it fits both the 3s motor and the surf box.. sweet, next up i removed the 2c flywheel and backing plate. (the 3s i have is out of a fwd car and the starter wants to come in from the gearbox side), the backing plate from the 2c motor should do the trick, also looking at it i might need to use the diesel flywheel to get the spacing right for the clutch.. id rather not as its pretty heavy - or would that be a good thing?
so next up is taking the flywheel off the 3s motor, getting a spigiot bearing to fit ( FWD ENGINE DID NOT RUN ONE).
looks like the 2c motor ran the same input as the surf so the 2c clutch plate will go into the 3s
next problem looks to be the clutch fork. - no probs if i run the diesel flywheel, but if i end up using the fwd flywheel its about an inch narrower and im worried that the clutch wont have the reach to work...
future problems- sump (unknown clearance) rear water outlet and distributor will need a 2lt icecream container sized hole in the firewall- (maybe use an old steel sump pan)- general oiling issues, as the 3s motor ran on a 10-15 degree lean in the fwd setup- will sort these once its in and running
radiator- unknows as of yet
power, this is a tough one HP should be up but torque will be down driveability wont be known till its running
electrics - unknown, would like to run original temp and rev counter + other gauges, shouldnt be to hard splicing into the surf loom
exhaust - down pass side rather than drivers side. should be easier
engine mounts - would like to use the 2l mounts if poss
weight.. just a guess but i would say the 3s MUST be lighter than the 2l motor or even the 3y

if all works well i can upgrade later to 3sge or even 3sgte
id also like to keep all work to a warrantable standard, the surf i have is pretty tidy and could be put back on the road
so factory parts used where poss

any advice will be greatly appreciated

tristan

[tristanp]

after getting the 2c flywheel up against the 3s crank, its not going to happen, the holes are about 1mm out, i did think about slotting the flywheel, but thats best left to the rangimods crew , ive used the 2c backing plate and put the original 3s flywheel and put the spigot bearing from the 2c straight into it- ive also packed the clutch fork fulcrum with a couple of washers to get the travel back to where it should be.
i have used the 2c clutch plate (fits the surf box) and as it looked a bit beafier i have used the 2c pressure plate too ,all bolting to factory holes.
with the bellhousing mocked up on the motor the lower supports that run from the bottom of the block out to the bottom of the bellhousing dont fit any more, roll the van over again and the ones from the 2c bolt straight up

just need to sort out some radiator lines that have been removed and get the start of an exhaust sys and a new front cover and i will be ready to drop it in

thanks to timotheus who came out and helped man-handle the 3s off the back of the surf

[tristanp]

its all coming along nicley apart from two things, starter motor and exhaust manifold
i thought i would be able to use the 2c starter motor and perhaps change the drive gear for the one to suit the 3s motor.
well there is no way the 3s gear will even fit into the 2c starter as its at least 5mm bigger in diamater , and judging by the marks on the ring gear , what i need is less diamater , or an offset starter. hmm. the 3s came out in the cressidas in rear wheel drive.. maybe its time to look at one of those..
oh, and with the 2c starter in place if it was to work, it fouls the headder flange.
one thing at a time

[timotheus]

I wasnt meant to tell you this, knARSEhole has a 4S powered rona, the last of the RWD models. All you need?

[timotheus]

Hows the progress? Starter?

[tristanp]

well, im getting there. i have tried 6 starters now, and after pulling the bellhousing off and taking a proper look ive discovered a few things. ring gear needs to be turned around and welded back on, the 3s starter gear needs to go onto the 2c starter motor.the case of the starter needs to be machined out to accept the much larger gear
i have also discovered that 4age 20v headders fit onto the 3s head, clearing the 2c starter motor..

[tristanp]

oh that and the fact i have two (1 and a half really) ride on mowers in the garage.. i can barely move in there...
anyone know how to get cheap john deere parts?

[tristanp]

so i did some thinking and decided to go back to the 2c starter
all i needed to do was have the 3s flywheel machined to accept the 2c ring gear
automotion in hillside rd dunedin did this for $50, put the flywheel back on

the headers are pretty close to the starter so i removed them and bolted the 2c bellhousing up and tried it

presto, we are up and running again
i started work on the engine mounts (used 7m? ones i think), the holes were close so used the die grinder and a carbide burr and made it fit. problem now is the 20v headers hit the engine mounts.. time for another rethink. i will get a set of 3sge headers tomorrow and see how they look, failing that i could bring the collector on the 20v extractors up above the starter..., the standard 3s manifold will not fit over the starter now, so thats out