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, did you ever get the feeling the automotive gods gazed down on you and with a twinkle in their omnipotent eyes and smirk they say..."he is not worthy, smite him and cause him pain!!" Yep, I would be the ire of which they speak, the sliver in their finger, the thorn in their side, the fly in their chardonay...

So, I finally got the endplay worked out and had the case cleaned as well as the broken oil dipstick tube removed. The plan was to assemble today, drop off at Christoph's tomorrow and pick up a running car upon my return from Scotland. Well, we have a saying in the Army, maybe I have said it before, I can't remember but, it is simply, "no plan survives first contact." (IMG:style_emoticons/default/ar15.gif)

This is why we develop contingency plans, branches and sequels...That may work in tactical operations but it doesn't do so well with motor assembly. I came home at lunch, cut the grass and then slapped in the crank and put the two case halves together to check end play. Now, my son is now gone, he is probably getting yelled at right now by a drill sergeant so I don't have a second set of hands to help me out. No problem, carefully line up the bearings, check to make sure they are in the correct position, feels good, looks good, must be good! NOT! (IMG:style_emoticons/default/lol-2.gif) (IMG:style_emoticons/default/lol-2.gif)

Crank turns easily and the bearings don't rotate. I am positive number 3 and number 4 are seated and number 1 isn't moving either. Put on the other half and torque the 6 thru bolts. Damn, she doesn't turn! Hell! now what. OK, don't panic, loosen the nuts, take the case apart and make sure things are seated correctly.

hmm, crank still won't turn, damn, I gotta go back to work. Will check when I get back.

So back to work, leave at about 1500 and head home to work on the motor. Pull the crank out of the case, dang, the #1 bearing is stuck! This isn't good, well a little tapping and she comes off. Inspect the crank, no burrs or any damage, inspect the bearing, dang its damage! You can see where its pushed in just a bit and an edge flat. What the hell just happened?! (IMG:style_emoticons/default/WTF.gif)

Well it took me a bit until I figured it out, well, I hadn't noticed it before but there is small hole right next to the dowel pin hole that is just a bit shallower but the same diameter as the dowel pin. Sooooo, when I was checking to see if the bearing was seated it was in the shallow hole and not the correct dowel pin hole. (IMG:style_emoticons/default/headbang.gif)

Because of this when I put the case together and torqued it down the pin pushed the bearing in. Guess I need a new #1 bearing. I can't seem to catch a break on this car! It's a good thing I have become much more patient as I got older or I would have probably torched the car and motor by now. (IMG:style_emoticons/default/blink.gif)

So, tomorrow, since I have off, I will be scrambling to find a new #1 bearing. If I can find one then I can get the motor assembled and get it to Christoph's shop Saturday morning. If not, I'll get it on order and put it together when I get back from Scotland. I will run over to the VW dealer in the morning and see what they can do for me. Wish me luck! In the meantime, I'm gonna drink me a Belgium beer and clean the house so I don't have to do it tomorrow before I depart. (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif)