Further Dissassembly

From pcarworkshop

This article deals with getting into the deep insides of the engine. Since I went so far as taking the heads and barrels off I decided to split the case and check things out. I do not have much info on how the car was treated before I bought it, and for not that many more dollars (lots of time though) I could go to the bottom and then I will know 100% what is in this engine...so I took a deep breath and way I went.

First job it to start removing the pistons. You can remove the cam carrier and three pistons as a unit or do it this way...its up to your approach. I prefer to do it in smaller chunks...so first of all you raise the cylnder up and off the piston (carefully...).

The wrist pins are kept in using a nasty tight spring which can come out at high velocity..I can't wait until I have to put the new ones back again....

Pull the wrist pin back a bit and slide it off the rod...here is the rod end poking out. I had to build a tool to get the pin to move...its pretty well machined and nice and tight to the pistron. The wrist pin bushing looks good and no marks/scratches...I start to wonder why I am here...oh yeah because I am picky and want to know it down to the bones...and its raining outside anyways...

Here is the inside of one of the cylinders....the good German Hans handiwork is still visible as the scoring lines down the walls of the cylnder which means that they are in good shape and he was not drinking too much beer that day.

Pulling another P/C off..you work from the front to the rear of the engine so you can get the wrist pins off. Just reverse for assembly right?  :roflmao:

Here is the nasty Dual Mass Flywheel (DMF) which is a piece of junk and I will give to a boater friend of mine to be used as an anchor...wait that is too dignified for it...how about a test holder for a piece of exposive?

Removing the pressure relief valve...

Damn stuck and rusty nuts! This one was tough...it was frozen together and the spot did not lend itself to using a grinder (although I could I would rather not with an open case). I ended up using visegrips and my hands-of-steel (Tm) to twist the little bugger off....and then promtly throwing the bolt/nut into the garbage with a little yell of victory when I was done...

Ok, top half of the case is off....its like looking into a ancient tomb. I spent a few minutes in silent prayer (mabye I should have done that a few days ago..) and then dove in.

I am now checking the backlash of the layshaft gears as a check before it comes apart. It appear to be in spec and everything looks OK so far.

Links to Rebuild Tour

1. Getting started, dropping the engine and superficial stripdown
2. Checking the default timing and Cams
3. Looking at the heads and the SAI passages
4. Valve guides, valves and carbon
5. Further Dissassembly
6. Exploring the SAI passages
7. Cleaning and getting ready to put it all together again
8. Rods and last minute checks before putting the case together
9. Sealing the case (or tomb)
10. Putting the pistons/cylinders back
11. Camshaft timing Part I
12. Camshaft timing Part II
13. Messing up a clean looking engine
14. Not quite there
15. Cranking it up