Steve's unending Progress thread, Air compressor setup recommendations Options

[stephenaki]

OK, this will be the thread that I keep updated as I make progress. I showed up at 0800 at Christoph's place and he was ready for me with a not so glamorous chunk of metal that is my cars heart and soul.

With a little assistance, we loaded it into my Toyota Sienna, not quite I envisioned a mini-van for, and I was headed back to the house. Upon getting home I had to first make coffee then clear out some space in my tiny German garage. So that everyone has a frame of reference to the area that I am working in I have enclosed this lovely 4x6 glossy of my garage in Germany.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747638.1.jpg)

And, for those of you not familiar with the Toyota Sienna, a shot of the engine in the back of the van. There's a lot of room back there for the motor but, it is awkward to get in and out of when loading a motor.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747639.2.jpg)

Now to summarize what was accomplished on the 4th of July, engine brought home, tin, impeller and housing, exhaust, cylinder head and cylinders removed. I had difficulty removing the impeller hub. OK, I didn't get it removed, will need a puller and I don't have one unless anyone can give me any ideas how to get it off without a puller.

Now for the requisite pictures of the motor unmolested.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747639.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747640.4.jpg)

Now based on the initial tear down two problems presented it self first the primary issue with a lack of compression...HOLY SHIT!!! Here is what I found.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747641.5.jpg)
(IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif)
Now the cylnder itself was not pitted, it had a build up of corrosion but otherwise in good condition. So I was thinking, maybe I can just clean hone and replace the piston. Well that thought went out the window when I pulled the cylinder directly opposite to it. As you can see by the photo, problem #2.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747642.6.jpg)

More importantly, where did that piece of metal go? An initial look behind the piston shows a knick in the inner portion of the crankcase.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747642.7.jpg)

I will see if there is more significant damage when I split the case; so it begins and were off to a rocket start here at the 914 follies! Stay tuned for the next exciting episode of "never buy a car sight unseen" later in the week! (IMG:style_emoticons/default/happy11.gif)

Gonna go shower and start working on the motor some more. Plan is to have it completely torn down befor the end of this weekend. I will load up some pictures to my photo bucket album and post the link a bit later.

[stephenaki]

Well, after a couple of weeks and a motorcycle trip to Scotland and back I'm back on track to finishing the motor. I received the new set of crank bearings yesterday from Type IV and got a chance to fit everything together today.

I would have done it yesterday but, I was a bit immobile. I pulled my lower back out of wack at the gym so couldn't really do much other than hobble around and lay around. When the bearings came in it was a bit of a slap in the face as the box looked at me and said, 'HA, WHATCHA GONNA DO ABOUT IT BROKE DICK!!!!' (IMG:style_emoticons/default/bootyshake.gif)

Well, what I did about it was go see the Doc on post who proceeded to unpretzel me with some chiropractic type moves. He said my spine and miscellaneous bones were out of wack and he proceeded to correct that.

It wasn't until I left the office though and stuck the Tens machine on me that the pain went away and I was able to actually do shit! WOOHOO!! (IMG:style_emoticons/default/piratenanner.gif) First things first, check to make sure the bearings are the right size! Yep, now, put the half up with the dowel rods and fit all the bearings properly then mark them!

After that I spent the next couple of hours hand cleaning the mating surfaces and transferring some studs from the old case halves to the new one. Once everything was cleaned up and dry I began to assemble the case with bearings to check endplay. This time I make sure everything was lined up and the crank spun freely before I torqued it down.

That went well but had to have the wife help me get the assembled case down from the work bench. Normally an easy task for me but not when you have a hurt lower back and don't want to re-injure it.

Slapped on three shims, thick ones all at .38mm, torqued the flywheel down and took some measurements. .004mm WOOHOO!! (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/piratenanner.gif) I didn't mess with it anymore but I have more shims than I can shake a stick at in some smaller sizes so all I have to do now is mix and match till I get the right measurement. I will do this tomorrow but sitting on the ground made my back sore so stopped for today.

Hopefully things will go well tomorrow and I can start final assembly; keep your fingers crossed!