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]

OK, after a slow start this morning, I watched Mongol instead of working on the car, good movie by the way, I headed out to tackle the teener again.

First, lets adjust the shift linkage. Boy what a PITA! Whoever designed the access panel and clamp assembly needs to be shot! Got it done but I am surprised I didn't throw out my back doing the different contortions to get to the bolt and nut on the clamp.

Next, pull the cylinder cover and check torque of nuts. Oh crap, I forgot, If I want to get some of the nuts I gotta take off the tin! Well, lets check the couple I can reach. Yup they were good so I am pretty sure head to cylinder torque is not the problem.

So, lets start her up and take her for a spin, so she's running, so far no oil. Get in, push in the clutch, put her in reverse.....GRIND GRIND GRIND! What the hell? How about 1st? GRIND GRIND GRIND! Well that's not good.

OK, I clearly need to adjust the clutch cable as I obviously didn't get it right when I reinstalled it. So after some checking here and there I found where I screwed up and made the adjustment. Lets try again, OH HONEY! "WHAT?!" Come out here and push the clutch in so I can make sure it is engaging!

Out comes the wife, she gives me the long suffering look, I get under the car, "now?" Yes dear, now. She pushes, still a bit loose; send the wife on her way and make some additional adjustments. This time I clear everything out of the way again, start her up, clutch....put in reverse...WOOHOO! (IMG:style_emoticons/default/piratenanner.gif) Back her out of the garage!

Now, lets take her for a little spin shall we?! So I run her about 5 miles, get her up to about 50 and hit some stop and go traffic until I finally get back, about 10 minutes total time. Pull her in, leave her running and check under the car. All I got is an occasional drip with some splatter from the vibration of the motor. I still think she is coming from the #2 cylinder but it is very, very minor.

Well, before I re-attach the warm air guide and connecting tube, I plan to run her into work tomorrow which will be a good 15 mile trip that takes about 30 minutes on the back road. If I am getting just a minor drip then I am not going to worry about it. I'll just keep an eye on it and make sure it doesn't get worse. Should get me through the winter. I do need to make sure the HEs and the defroster work but I'll have to tackle that next weekend as I have a trip to Garmisch this week for a conference. No, not taking the teener, riding the bike down cause I'm a glutton for punishment! Should be a cold ride.

I am due to move in June of next year, she just needs to behave until I get her back to the states, once I get her back and have all my tools out of storage she can act up again. I am sure I'll have questions as I dig into the defroster and heating system, the saga is not over, just on temporary leave. (IMG:style_emoticons/default/lol-2.gif)

Time for a beer, especially since I am feeling much better and seem to be getting over the bronchitis. (IMG:style_emoticons/default/beer3.gif)