Immediate help required before I check-in to asylum

[BonnSSEi_Lass]

Hi guys, im seriously considering a strongly worded, profanity laden letter to gm about the lack of resources out there regarding all things Series-1. The next step would have to be tracking down the 'genius minds' of the engineers just to get in a satisfactory punch in the face. Really though, I have recently rebuilt the motor in BonnSSEi_lass as well as a full engine makeover, bay and all. Now I am at the finish line only to find that my 3yo daughter erased my reference pics from my phone showing me what the EVAP sys looked like prior to teardteardown, line routing from canister by the washer fluid bottle to trans to SC gadgetry an on to firewall hookups. I'm bald at age 40, and not by simple misfortune but rather from the last 3 days of pulling it out! Lol.

Diagrams are no good to me bc I'm a picture type of learner, yet searches I've done to the far reaches of the interwebs lead me to believe that the series1 really never existed; like it's some sick joke left behind by John Titor in one of his visits from an alternate time, or that we have some experimental engine leaked accidentally from gm in the mid90s.
So is there any1 out there with a 95 SSEi who can please send up smoke signals, post pics, or better yet, text me the pics to (740)577-5683 before I seriously push Bonnie to the front yard with a 'free' sign in her? I'm talking about complete and detailed images that show the routing of your vacuum lines from the canister by the washer fluid bottle all the way on their stops and connections back to the firewall. A drawing labeling the parts would even work i suppose. until that time I will be just like this little emoticon down here...

[RJolly87]

This is the most help I can be, however it doesn't have everything that your application will have.

http://www.pontiacbonnevilleclub.com/fo ... gine%20bay

[BonnSSEi_Lass]

It does help some. Sorry took so long to get back, been salvaging some useable lines and such off of my jeep. After my phone charges up a little I'm going to send a picture of my evap canister and maybe you can tell me where this line is supposed to go. Underneath the port for the line on top of the canister it says "air" in all caps. I don't have any open connections anywhere on the firewall or the motor so I'm thinking maybe I might have a routing issue something might be done wrong I'll get back as soon as I can, it will be tonight though thanks for the pics they did help. Hopefully get her rolling to roads tonight.

[BonnSSEi_Lass]

Ok I had her to where i felt confident to do first fire up. Grandpa taught me to keep stopwatch at this point of rebuild an after giving it 2 full spark-free rotations to lube her up good, I kicked it over. 24 sec into a shaky idle, both manifolds were red hot. So hot the 2000 degree header paint started to broil an smoke off. Engine temp rose to maybe 240 really fast, never got to time it. Check engine light came on but cannot find my scanner to see what's up. Seen this a few times before, and the culprit was one of three things; packing left behind in head after painting causing blockage, converter clogged, or o2 sensor bad causing rich mix to burn out the exhaust cycle in each cylinder. Am I missing anything else I should check? Was thinking that packing would have to be left in both heads for both manifolds to light up like that so fast an air in cooling system could cause engine temp at gauge to rise so quickly but at a loss after being up all night double antriple checking different things. I appreciate the help so far an I know something serious is going wrong just too tired to get at it right now.

[skregal]

I have a 95 factory service manual. I could copy some pages out of it
if you think that would help. It will have to wait until I get home tonight.

Are you saying the motor went from cold to hot in only 24 seconds?

Air in the cooling system is sometimes a problem on this engine. There
is a procedure to help purge it. Do a search on the forum.

If the cat wasn't clogged before seems unlikely now unless you
left the exhaust open during the rebuild and something got in there.
I guess you could disconnect it next start-up and rule that out. PITA though.

[J Wikoff]

I'd help with vacuum line pics, but I'm not sure my 92 is the same as a 95.

Double check your spark plug wire routings.

[BonnSSEi_Lass]

Well guys, I'm bald but i have the line routing figured out. This model i have had been a nightmare in the way of finding parts. Seems like it is a mashup of 94&95 year parts; and now I am at the juncture where i need to decide to switch to an OBD2 COM or try to deal with the current, and totally frustrating 1.5 system... thanks to GM for that one. What I am most frustrated with is that this rebuild/engine makeomakeover was decided while I was waiting on the rebuild kit for the SC snout. The coupler was definitely bad bc the pulley could be turned at least 1/4" either way before itd catchup with the innards. Had that rattle to it at idle but dissipated with increased throttle applied.
So last night I was sure I had my worries behind me until I fired her up just to find the same rattle i set out to eliminate a month or so ago lol. Have to laugh on that or id definitely go insane.
At visual inspection i can see a little jump in the lower tensioner pulley, sometimes worse than others, and the rattle is definitely coming from that general location. I know that means nothing as bad parts in the rear of a vehiclecould cause you to believe the issue is up front. So I took the belt off that drives the alt, ps pump, etc... and the noise vanished. Now I'm thinking harmonic balancer. First I plan to replace the tensioner with a good one I have lying around before I just into that work. Just wondering if you guys know of any little owner secrets or other tests i should do prior to setting my mind on the BBC.
Thanks again for the help to this point. This car could be totalled and on fire an i wouldn't give up on her.