T-minus 21 days (Long)

[Eric]

Well it is 21 days until the due date of our first child and our family
car is still on jack stands.  I have been spending almost all of my
waking hours (when I don't have to be at work) on the car.  I am getting
very close, but I have a number of questions.  I am hoping that with
some help from you guys I can drive it this week.

The swap is a '85 KH engine into a '85 4kq - more detail on my site.


Current big headache -- Vacuum lines

I am at a bit of a disadvantage since I have never seen under the hood
of a 5k.  I have both Bentley manuals.  I am considering ignoring the
emissions system for now.  I don't fully understand how it works and
thought leaving it off might be best for now.  Any thoughts?  Should I
just get caps and plug off the lines where they come through the fender
wall?  I would like the car to comply with emissions eventually (it has
a cat), but it is not tested in my area so there is no urgency.

As an extension to the vacuum problem I have a question about this
vacuum switch on the side of the head at number 5 cylinder.  Is it
supposed to have two hose barbs on it?  I have two of these and they
both have just one barb and one hole, but it looks like a second barb
was broken off?  It seems to be something to do with cold enrichment.
Does anyone know how this subsystem works or can they point me to a part
of the Bentley that describes it?

Another question... The Bentley does not show a check valve between the
engine and the differential lock system.  Should there be one?

On the crankcase ventilation system one of the ports connected to the
valve cover appears to have a check valve.  Where is this connected to?
The Bentley is not clear on this.


The blue wire...

I have been unable so far to figure out what the blue wire does.  There
is a blue wire that connects the left side engine harness with the right
side harness (near the CIS fuel distributor).  It is connected by a red
single blade waterproof connector.  I have not broken out the multimeter
yet as I thought someone might know off the top of their head.  The only
thing I have found so far in the wiring diagrams that has a blue wire is
the field for the alternator.  The reason I ask is I have rerouted my
harnesses somewhat and they are about 1.5" too short to plug into each
other.  If I still need it with the KH I will lengthen the wire.  Any
thoughts?


Coolant afterrun system

I am using the JT heater pipe on the side of the block.  I am also using
the KH heater outlet on the back of the motor (I could not get it out).
I am planning to use the one 1/2" pipe off the back originally for the
automatic tranny cooler as one of the points for the afterun pump.  I am
going to use a splice into either the upper or lower radiator hose for
the other.  My brain is rather fried by this project so I am unable to
figure out which would be better?  Any thoughts?


Misc

Does anyone know if the afterrun coolant pump and the injector fan
thermo-switches are set at the same temperature?  Has anyone run into
problems with not running the injector fan?


Thanks for the help!  I am sure I will have more questions as the week
goes on.


--
Eric Sanborn
'85 4kq - 225k+ (work in progress)
'8X VW Race Rabbit - EFI
'89 Honda CRX Si - 175k (Wife's car)
'88 Chevy Suburban - 190k (Tow vehicle)

http://www.mindspring.com/~robinsanborn/4000/