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, necessity being the mother of invention, I went out to tackle the tranny and motor marry up again. Cleaned the input shaft then put a light coat of grease on it to lube the pilot bushing. Lined up the jack then slowly brought it together. Dang, not quite lined up; back out the jack turn the input shaft just a tick then line up and try again. This time they seem to be mating well but I can't get them to slide together.

Hmm, maybe if I take a clamp and clamp both sides then slowly turn the clamp I can bring them together slowly without having to shove anything! So off I go in search of a clamp...damn, their all in storage! (IMG:style_emoticons/default/mad.gif) Now what? Hmm, ya know that one bolt is pretty long...wonder if I can get it through the motor and tranny case and just tighten the bolt? Should do the same thing as using a clamp; brilliant! (IMG:style_emoticons/default/aktion035.gif)

So, I thread the bolt through but it is a bit long so I take a wrench and thread the bolt through the wrench and then the tranny to the motor...BINGO! Start to tighten and she begins to slowly move together. Stop and check alignment then grab both sides and try to slide them together knowing that it ain't gonna happen...Well hot damn! Slide together like a a well greased........Yeah, well leave it at that. So, I got the motor put back together and began the process of re-mounting the motor to the car. Here is where I have a question.

I got the car and motor lined up and the tranny mounts were easy but I don't think I have the engine mounts quite right. According to the PP diagram:


I should have only one number 15; well, I got two on there. One facing cupside down and the other was on there cupside up and covering the rubber mount. This has caused a problem with getting the dang bolt through the mount, base upper and washer as it doesn't provide me much room to thread the nut onto the bolt.

Any reason I should leave the second base lower on there? Based on the diagrams I only need one base lower and it fits cupside down with the notch pointing inward towards the motor. I am hoping I can get the car back on the road either tomorrow or Sunday as I have to take my bike in to get the front wheel re-balanced and an oil change so need trans!

Now, once I get the mount installed properly, 21ft lbs of torque? That is what Haynes is showing but I am not totally sure and it is a royal PITA to get in there to torque the damn nut. Any help from the peanut gallery would be appreciated.