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]

So, I took the time to replace all the O rings on the #1 and 2 cylinders today. When everyone says it is easy well, that is a matter of opinion. #3 and 4 side is bone dry, just the 1 and 2 cylinders that had oil leaking from what I could tell.

Since I wasn't sure which one, I replaced all the O rings. 4 hours later I had it started and idling up on the lift. I didn't see any oil form under the cylinder head as I did before and I let her idle for at least 10 minutes. I did see oil forming on the bottom front and rear seam of the crankcase though. So maybe I didn't seal the crankcase as well as I thought? Can I through on any type of sealant that over the seams that will keep her from leaking?

The oil is still hitting the exhaust when I stop and smoking and I have an exhaust leak in the number 1 cylinder. I will put her up on the lift again later and see what I can figure out.

It looks as if I'll be keeping the car, I had put it up for sale on 914freunde.de but haven't had any interest and truthfully, I don't think I can sell her as long as she has the oil leak problem. Unlike the PO, I have a hard time passing a problem off to someone else so will probably pull the ad.

What I really need is a weekend where I can drop the motor and check both seals to make sure they aren't leaking. I have two new seals that I got when Christoph also ordered some gaskets for me.

If anyone has some ideas on sealling the seams without cracking open the crankcase again I am all ears!

[Bleyseng]

So, I took the time to replace all the O rings on the #1 and 2 cylinders today. When everyone says it is easy well, that is a matter of opinion. #3 and 4 side is bone dry, just the 1 and 2 cylinders that had oil leaking from what I could tell.

Since I wasn't sure which one, I replaced all the O rings. 4 hours later I had it started and idling up on the lift. I didn't see any oil form under the cylinder head as I did before and I let her idle for at least 10 minutes. I did see oil forming on the bottom front and rear seam of the crankcase though. So maybe I didn't seal the crankcase as well as I thought? Can I through on any type of sealant that over the seams that will keep her from leaking?

The oil is still hitting the exhaust when I stop and smoking and I have an exhaust leak in the number 1 cylinder. I will put her up on the lift again later and see what I can figure out.

It looks as if I'll be keeping the car, I had put it up for sale on 914freunde.de but haven't had any interest and truthfully, I don't think I can sell her as long as she has the oil leak problem. Unlike the PO, I have a hard time passing a problem off to someone else so will probably pull the ad.

What I really need is a weekend where I can drop the motor and check both seals to make sure they aren't leaking. I have two new seals that I got when Christoph also ordered some gaskets for me.

If anyone has some ideas on sealling the seams without cracking open the crankcase again I am all ears!

rear crankcase seam leaks ususally are the rear main oil seal leaking past the flywheel sometimes the sealing surface on the flywheel is scored creating a leak.
I was just in Stuttgart to see the Porsche Museum!

[stephenaki]

rear crankcase seam leaks ususally are the rear main oil seal leaking past the flywheel sometimes the sealing surface on the flywheel is scored creating a leak.
I was just in Stuttgart to see the Porsche Museum!

OK, your not making me happy here! (IMG:style_emoticons/default/blink.gif) At least I have a couple of new seals that are still good. I am definitely keeping the car so will have to pull it off the other site. I am working on setting up a 3 day that I can park the car in the autocraft lift bay and drop the motor, inspect and fix oil leaks, then put back in the car.

HEY CHRIS WANNA DO A 3 DAY IN STUTTGART? He, he, he...Gustl, how about you? Probably won't be until after Mid-September as I have an Ireland and UK trip planned in a couple of weeks.

So the new priorities on the car are as follows:
1. get windshield trim and fix leak
2. fix oil leak
3. start taking care of spots of rust that are bubbling the paint
4. replace rear trailing arms

Let the madness begin...again (IMG:style_emoticons/default/rolleyes.gif)