St3alth's VR Calais

[St3alth187]

St3alth's VR Calais

Hey guys. My first ever car, paid probably a bit too much for the condition it was in.
$1000 - No RWC. Was a local purchase so no hidden travel costs.
I knew that it would need a little work, but it was love at first sight. I figured it would be something to learn on.. And learn i have.
Everything I have done and plan to do is possible because of the enormous database of information this forum has.

The 'Lais



Needs a little work, but she'll get there =)

3.8L Manual V6 Calais
Exterior

• Blue over Silver two tone.

Interior

• Leather/Velour Seats and Door trims.

• Black headlining

Engine

• HSV OTR CAI

Exhaust

• 2.25" Catback Exhaust

• Custom Extractors

Problems:

• Engine loses power on right hand turns below 1/2 a tank | Done:New fuel tank + sender

• Shifter grip is loose and needs to be replaced.| Done:Manual Conversion

• Randomly wont start when warm.| Done:New BCM + CAS

• Heater doesn't work.|Done:

New heater core + hoses and tap

• Fuel gauge is shockingly inaccurate | Done:New sender unit

• Trip computer doesn't show on dash|

• Stalled at lights| Done:New CAS

• Theft Deterrent Signal Missing| Done:Manual loom

• Terminals Loose | Done:New Terminals + Renewed starter loom

• Knock Sensor probe broken.| Done:Manual Loom

• Rough Idle | Done:Service + New fuel pump

Future Mods

• T5 Manual Conversion Done

• VE Big Brake Upgrade

• Monaro 18's Done

• Blue LED Conversion

• Clear Side Indicators Done

• Suspension Package - SL All round.

• 27mm Whiteline Sway bar

• Nolathane suspension kit

• Replace dash with a Stato dash and colour code it.

• Leather Interior

• SS Kit

• S-Pack Bobtail

• Paint garnish body colour

• HID Conversion

• Mafia Window Tint

• Sunroof

• Monaro bonnet scoop

• Complete Paint Job - BMW Blue ( Avus Blue ) over Silver/White

• Long range fuel tank

• LSx Conversion

Work Done

• Replaced center console power window switches - 23/06/11

• Replaced headlining - 23/06/11

• Replaced sun visor clips - 23/06/11

• Replaced Ignition barrel - 18/07/11

• Full Service - 12/08/11

• Installed Extractors - 10/08/11

• Installed HSV OTR CAI - 10/08/11

• Replaced Sway bar link pins - 16/09/11

• Replaced Fuel pump - 16/09/11

• Replaced O2 Sensor - 16/10/11

• Replaced Inlet manifold gasket - 01/01/12

• Coolant Change - 05/01/12

• Replaced drivers side window regulator - 10/01/12

• Replaced DFI + Coilpacks - 17/01/12

• Replaced Fuel tank + sender 07/02/12

• Replaced BCM + Keyhead 20/02/12

• Renewed Starter Motor Loom 27/02/12

• Replaced Battery Terminals 27/02/12

• Oil Change 27/02/12

• Monaro 18's + New Tyres 02/03/12

• Installed Clear side indicators 09/03/12

• Replaced CAS 21/03/12

• Replaced Rear brake pads 27/03/12

• Manual Conversion 31/03/12

• Full Service + New Leads 31/03/12

• New starter motor 31/04/12

• Reconditioned T5 + New Exedy HD clutch 25/06/12

• Installed statesman dash + door cards + heater core 09/07/12

• New heater tap + All cooling hoses 15/07/12

Thats it for now, but keep an eye out if your interested. Mods will be on the way as funds become available.

Cheers, Jake.

[GothicKidd]

Doesnt look like its had the best life.. but with some TLC it will come up a treat I recon! :P

[St3alth187]

Thanks mate =) The work i've put into it has really shown through already. I'd really love to clean her up =) Buff out the wrinkles; so to speak

Pictures will be up shortly.

[VS_Pete_1]

Will be a good project to work on mate.

[St3alth187]

• Removed the sagging headlining and replaced with black velour following COINERS How to:

HOW TO replace headlining - Very detailed

• Heat cleaned all the seats, door cards and carpet. The filth that came out of it was disgusting. Would have never been cleaned in its life.

[St3alth187]

On close inspection of the heater hoses, it appears that the heater has been bypassed completely.

Not fun. Will reconnect the heater some time in the near future to inspect why this has been done. Suspecting a shot up heater core.

I have also replaced my ignition barrel which did not resolve the starting problem. Im lead to believe that this is BCM related, so im going to inquire about replacing that with a brand spanka from Holden with new key.

Cheers,
Jake

[Mbro]

yer sounds like they have bypassed it because of a heater core.

otherwise looks good. decent base to start from.

[St3alth187]

Paint will be done after all the little things are done and my car is in top working order. Also after the manual conversion ! Taken a long time to decide but have ultimately chosen to go with BMW Blue. Cant wait.

Replaced the drivers side window switch, window still doesnt work... Not sure whats going on there. Thinking about taking the motor out and seeing if it allows current to flow through it.

Any suggestions ..? The Auto Mirrors dont work either... checked the loom at the hinge... Everything i could see seemed to be okay.


EDIT: Checked the power at the motor, there was none. Fuse proved to be faulty and the motor was burnt out. Replaced window regulator and its all good now. Just doesnt go up and down straight.

Cheers,
Jake.

[vsl67]

St3alth's VR Calais

Things that are wrong with it:

• Engine goes back to idle on fast right hand turns, below 1/4 of a tank. Depending on speed, will often stall.

Sounds like your return hose to the fuel pump has broken or come inside your tank off especially if its doing on turns or going up hills will a low tank lf it has broken it easier to replace the tank than the hose

[St3alth187]

Replaced the fuel pump, it no longer dies around corners. There was alot of build up around the pump.. Wasnt nice at all.

I think it may have fixed my starting problem too.

Replaced my sway bar links with Heavy Duty Selby links.


EDIT: Problem isn't fixed. There must be something internally wrong in the fuel tank, maybe a return hose disconnected. vsl67 was right Looks like a new tank is on the list too.
EDIT: New fuel tank + sender and the problem seems to be solved. When my car is hot it seems to surge a little but ... Im suspecting something electrical related.

[St3alth187]

Just fitted Extractors to the old girl, had a bit of trouble as this was a new experience for me. Was a nightmare to say the least.

The note was well worth it.

Added a VS HSV CAI to the system.

Right now it has Extractors through custom 2.25" catback exhaust.

Gave it a major service, filters, Oil, Plugs. Just need to get this New O2 sensor in :/

Cheers,
Jake.

[St3alth187]

Been a while since i have posted, been busy - just finished school

I've been poking along fixing things here and there..

Still having trouble with it not starting once its warm ( every now and again )

Replaced the Inlet Manifold Gaskets and removed the bellmouth. I do notice a different note and slightly more throttle response but nothing that can be measured.

Coil Packs + DFI Module are on their way.
Since i bought the car the drivers side window and RHR Lock wont go up or down, so i went ahead and bought a RHF Window Regulator.
Hopefully they show up sometime soon.

SOON TO BE MANUAL ! Go to pick it up in the next couple of days

Cheers,
Jake.

[brad3394]

sounds like its all coming together man, and it sounds like a nice car now. the interior clean really made the inside sparkle and the little od jobs youve done are good man.

how the exhaust sound with the pacemakers and the redback on your auto, was is droney at all?

cheers, Brad.

[St3alth187]

Thanks Mate. Been a work in progress... However i've encountered a few more set backs in this heat

Yeah the extractors added a nice note to it in the higher rev range like 3.5-5. Being an auto it does sound like a boat though.. Although I've heard worse.

Its not as bad as you may think, I havent got a redback exhaust, just a custom made one at 2.25". The smaller diameter uses less fuel around town and doesnt make the "drone" sound as bad.

[brad3394]

Thanks Mate. Been a work in progress... However i've encountered a few more set backs in this heat

Yeah the extractors added a nice note to it in the higher rev range like 4-5. Being an auto it does sound like a boat though.. I've heard worse though.

damn bro, thats no good, goodluck aye.

ohh yeah, sounds alright bro, im kinda not wanting to get an exhaust for my auto cause it drones and doesnt rev high.

[St3alth187]

Ill be able to tell you the difference soon, just did a 1400km round trip to pick up my manual conversion.

Picked up a nice clean box with tight gears + Everything else including the center console for $450.
Only problem is that it was out of a VN S1 so ill need an adaptor kit for the flywheel.. Or a new 8 bolt flywheel.
Anyone got one they are willing to sell or trade ?

Not sure how im going to go with the electric side of things or how much modification i will have to do with the Manual loom/ECU i picked up.

[VRCALAISS]

looks like my vr calais when i first got it a year ago,you didn't pay to much lol,an i wish i had the problems you had.

i had to replace my motor an 4 gearboxes,very expensive excercise it was lol.

as for your problems sounds like crank angle sensor is rooted,what codes is it throwing?

[St3alth187]

Ouch Well you've worked out all the problems now.. It looks like you've put some TLC into it.

Like i have posted somewhere around these forums... The problems i'm having are minor.. But they cause something major :P

Meaning; it cant be too bad because my car drives perfectly one day and then will play up the next.

After my incident out of town she threw:

43 - Knock sensor
56 - System running lean
68 - Auto Transmission Fault

Cheers,
Jake

[VRCALAISS]

Ouch Well you've worked out all the problems now.. It looks like you've put some TLC into it.

Like i have posted somewhere around these forums... The problems i'm having are minor.. But they cause something major :P

Meaning; it cant be too bad because my car drives perfectly one day and then will play up the next.

After my incident out of town she threw:

43 - Knock sensor

56 -

68 - Auto Transmission Fault


Cheers,
Jake

yes alot of tlc lol

43 - Knock sensor

Check the resistance of the knock sensor. VR knock sensor should read about 3.8K ohms. If it reads 100K ohms then someone has fitted a knock sensor off a VS or VT ecotec which would set Code43 on a VR.

Dick

56 - System running lean i'd say that's an 02 sensor which can cause stalling,probs best to replace that as there supposed to be every 100,000km

68 - Auto Transmission Fault
your new manual box will fix this basically the auto is rooted.


DTC 68 will set if:
. Throttle position 0%-50%.
. TFT between 20 degrees C - 115 degrees C.
. TCC is enabled.
. 3rd or 4th gear is selected or indicated.
. Trans slip speed is greater than 200 RPM for 10 seconds.

[VRCALAISS]

your calais should have factory steering wheel air bag,i noticed it doesn't.

[St3alth187]

Yeah it came with the car... minus the airbag. The idiot i bought it off set it off somehow ... So he pulled it off.
Mines got the executive wheel on it. Been looking for a Calais wheel. But then again... If im down an airbag.. I may aswell put a sports wheel on it.
Stupid i know.. But seeing how it doesnt have one anyway..

[scvs6]

Hey mate, you have a nice car as well haha

Just wanted to tell you though, you do realise that its unroadworthy with that steering wheel on it. The car had an airbag fitted from factory so it has to still have one. That could be why he sold it to you without a roadworthy.

When you say that it sometimes wont start when warm, that might be either the Crank Angle Sensor or DFI Module on its way out. With my VS, when the DFI module went on it, the engine used to cut out when it got to operating temperature, and then woundn't start until it cooled down.

Also the heater would have been bypassed because the core would have been leaking. The reason they bypass it instead of fix it is because you have to pull out the whole dash just to change the core. It's a big job and costs a bit to get done as well.

Anyway, I can't wait to see it once you have done the mods, and let me know how hard or easy it is to take the dash out and put a statesman one in. I would love to do that to mine but have no idea where to start. I'll be watching this thread for updates as well haha.

[VRCALAISS]

Yeah it came with the car... minus the airbag. The idiot i bought it off set it off somehow ... So he pulled it off.
Mines got the executive wheel on it. Been looking for a Calais wheel. But then again... If im down an airbag.. I may aswell put a sports wheel on it.
Stupid i know.. But seeing how it doesnt have one anyway..

ok lol,there way easy to fit statesman bolt straight in lol,i'm just not sure if you can get in shit for removing stuff like that lol.

[St3alth187]

Just wanted to tell you though, you do realise that its unroadworthy with that steering wheel on it.

Thanks mate, I got it registered in NSW about a week after i bought it. I know the local mechanic that does the inspections. Good bloke.
The police aren't too fussed with things like that out here. As long as your not doing stupid stuff they leave you alone.

that might be either the Crank Angle Sensor or DFI Module on its way out.

I got S/H Coil packs + DFI Module in transit to my door. Ill be sure to let everyone know what the solution is once i've worked it out. Next option is my keyhead.

there way easy to fit statesman bolt straight in lol,i'm just not sure if you can get in shit for removing stuff like that lol.

Thanks for the concern Ill be on the lookout for an original wheel, Best have a look at the sensor while im at it too.. I imagine its wrecked like everything else.

[scvs6]

Thanks mate, I got it registered in NSW about a week after i bought it. I know the local mechanic that does the inspections. Good bloke.
The police aren't too fussed with things like that out here. As long as your not doing stupid stuff they leave you alone.


I got S/H Coil packs + DFI Module in transit to my door. Ill be sure to let everyone know what the solution is once i've worked it out. Next option is my keyhead.



Thanks for the concern Ill be on the lookout for an original wheel, Best have a look at the sensor while im at it too.. I imagine its wrecked like everything else.

Oh sorry mate, I didn't even look what state you were in haha. Yeah it is unroadworthy in Victoria but i'm not sure about the other states.