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> Steve's unending Progress thread, Air compressor setup recommendations
stephenaki
post Jul 5 2008, 04:39 AM
Post #1


Can I get this one dad??
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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.
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stephenaki
post Oct 2 2009, 01:42 PM
Post #2


Can I get this one dad??
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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:
Attached Image

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.
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stephenaki   Steve's unending Progress thread   Jul 5 2008, 04:39 AM
Gustl   Gonna go shower and start working on the motor so...   Jul 5 2008, 06:18 AM
hcdmueller   This whole scene looks very familiar. Your garage...   Jul 5 2008, 07:04 AM
Gustl   Gustl, I can't wait to see pictures from Aust...   Jul 6 2008, 06:49 AM
Vacca Rabite   I bet you will find all that metal in the sump whe...   Jul 5 2008, 08:59 AM
ericread   Get serious. With a bit of Mother's, it'l...   Jul 5 2008, 02:09 PM
stephenaki   OK, so I didn't get as much done today as I wa...   Jul 5 2008, 03:23 PM
Gustl   Gustl, Sorry I didn't make it to Toni's s...   Jul 6 2008, 06:51 AM
Dave_Darling   Impeller hub: Get some fender washers or other la...   Jul 5 2008, 10:59 PM
stephenaki   Impeller hub: Get some fender washers or other l...   Jul 6 2008, 01:42 AM
stephenaki   Case is split! :D So after we ran around thi...   Jul 6 2008, 01:29 PM
!   If you're married to that motor, get LN Engine...   Jul 6 2008, 01:55 PM
stephenaki   If you're married to that motor, get LN Engin...   Jul 6 2008, 02:51 PM
hcdmueller   New 96mm pistons and cylinders are available at Ja...   Jul 6 2008, 05:04 PM
Jake Raby   New 96mm pistons and cylinders are available at J...   Jul 6 2008, 06:02 PM
stephenaki   New 96mm pistons and cylinders are available at ...   Jul 6 2008, 10:50 PM
ericread   I just need her running before it gets cold this ...   Jul 7 2008, 03:31 PM
Dr Evil   [quote name='Jake Raby' post='1053123' date='Jul ...   Jul 7 2008, 05:02 PM
rick 918-S   [quote name='Jake Raby' post='1053123' date='Jul ...   Jul 7 2008, 07:10 PM
stephenaki   OK, in order to do the proper conversion that Ja...   Jul 8 2008, 01:06 AM
Smitty911   OK, in order to do the proper conversion that J...   Jul 8 2008, 09:58 PM
stephenaki   http://dprmachine.com/Html%20Files/cranks_type_4...   Jul 9 2008, 01:00 AM
ME733   [quote name='Jake Raby' post='1053123' date='Jul ...   Aug 16 2009, 06:32 AM
r_towle   I agree. what parts do you need? I am sure we all...   Jul 7 2008, 05:37 PM
kwales   Buy a new one- dstributor gears are cheep. They m...   Jul 7 2008, 07:50 PM
stephenaki   OK, edumacate me everyone. I looked at the site t...   Jul 9 2008, 02:06 AM
stephenaki   Two things to update today; first is status of cra...   Jul 13 2008, 03:28 PM
stephenaki   OK, so after doing some studying yesterday morning...   Jul 20 2008, 09:44 AM
hcdmueller   Glad to see you are making progress. I feel your ...   Jul 20 2008, 06:17 PM
r_towle   To answer your question regarding the valve guides...   Jul 20 2008, 08:12 PM
stephenaki   To answer your question regarding the valve guide...   Jul 21 2008, 02:12 AM
Smitty911   To answer your question regarding the valve guid...   Jul 21 2008, 02:34 PM
stephenaki   Well, the crankshaft and rods came in last week Tu...   Aug 9 2008, 09:19 AM
ThinAir   This is a great thread. I really appreciate all t...   Aug 9 2008, 04:36 PM
stephenaki   This is a great thread. I really appreciate all ...   Sep 10 2008, 01:15 PM
stephenaki   OK, I'm back from my adventures in the Republi...   Nov 13 2008, 07:09 AM
stephenaki   OK, Tin's back along with the fan housing and ...   Dec 9 2008, 06:59 AM
stephenaki   OK, I think my car has a curse on it or something ...   Dec 15 2008, 07:09 AM
Dave_Darling   Sounds like you got 1.7/1.8 bearings instead of th...   Dec 15 2008, 09:41 AM
stephenaki   Sounds like you got 1.7/1.8 bearings instead of t...   Dec 15 2008, 12:39 PM
stephenaki   Called Christoph today, again I need to reiterate ...   Jan 8 2009, 09:45 AM
stephenaki   The bearings are in and they fit! The crank is...   Jan 15 2009, 08:40 AM
stephenaki   Finally got around to getting some pictures of the...   Jan 16 2009, 05:38 AM
stephenaki   Progress is being made, slow, deliberate and educa...   Jan 25 2009, 01:42 PM
stephenaki   OK, so, after discussion and reading on deck heigh...   Feb 15 2009, 10:57 AM
stephenaki   Well, did you ever get the feeling the automotive ...   May 7 2009, 11:14 AM
stephenaki   Well, after a couple of weeks and a motorcycle tri...   Jun 10 2009, 11:20 AM
stephenaki   Well, after a full day the motor is 98% complete...   Jun 12 2009, 01:49 PM
stephenaki   Hot damn! After almost about a year and a half...   Jul 10 2009, 11:37 AM
Gustl   Hot damn! After almost about a year and a hal...   Jul 10 2009, 01:06 PM
stephenaki   Hot damn! After almost about a year and a ha...   Jul 11 2009, 08:01 AM
Gustl   I need to call him again on Monday as I forgot to...   Jul 11 2009, 08:48 AM
stephenaki   I need to call him again on Monday as I forgot t...   Jul 11 2009, 01:37 PM
roadster fan   :trophy: Love your persistence! Hope you ha...   Jul 12 2009, 04:50 PM
hcdmueller   Congratulations! I am really jealous. I got ...   Jul 12 2009, 08:11 PM
stephenaki   Well ladies and gentlemen, it's home. :Qarl: ...   Jul 17 2009, 08:09 AM
stephenaki   OK, I got a chance to check some things on the car...   Jul 19 2009, 08:19 AM
stephenaki   OK, I now know why the cost of living is so expens...   Jul 21 2009, 03:48 AM
Gustl   oh man, I'm really sorry about this :( I k...   Jul 21 2009, 04:17 AM
stephenaki   oh man, I'm really sorry about this :( I ...   Jul 21 2009, 04:19 AM
Cupomeat   Damn, This is a shame about the bill total and the...   Jul 21 2009, 08:35 AM
stephenaki   Damn, This is a shame about the bill total and th...   Jul 22 2009, 04:33 AM
stephenaki   So, I talked to household 6, for those of you that...   Jul 22 2009, 05:39 AM
hcdmueller   Sorry to hear this. I got back from my deployment...   Jul 22 2009, 05:55 AM
stephenaki   Sorry to hear this. I got back from my deploymen...   Jul 22 2009, 06:41 AM
stephenaki   OK, so I put her on the lift today to find the oil...   Jul 25 2009, 08:19 AM
Dave_Darling   Pushrod tubes: Pull the tubes halfway out of the ...   Jul 25 2009, 03:04 PM
stephenaki   Pushrod tubes: Pull the tubes halfway out of the...   Jul 27 2009, 06:41 AM
stephenaki   So, I took the time to replace all the O rings on ...   Aug 14 2009, 02:33 PM
Bleyseng   So, I took the time to replace all the O rings on...   Aug 17 2009, 01:51 AM
stephenaki   rear crankcase seam leaks ususally are the rear ...   Aug 17 2009, 10:53 AM
stephenaki   OK, the new windshield is in and trim is on, shoul...   Sep 23 2009, 01:09 PM
stephenaki   So, I was able to get a floor jack and some stands...   Sep 28 2009, 01:10 PM
stugray   HA HA! when I read the title of this thread I...   Sep 30 2009, 10:40 PM
stephenaki   2 hours my ass! :angry: So I found a CV join...   Sep 29 2009, 02:36 PM
stephenaki   OK, had to pull the carbs in order to get the axle...   Sep 30 2009, 12:20 PM
Dave_Darling   You're using the same method I've used to ...   Sep 30 2009, 11:02 PM
stephenaki   You're using the same method I've used to...   Oct 1 2009, 01:14 AM
Dave_Darling   I don't think I did, but I probably should hav...   Oct 1 2009, 07:01 PM
stephenaki   I don't think I did, but I probably should ha...   Oct 2 2009, 07:22 AM
stephenaki   Well, necessity being the mother of invention, I w...   Oct 2 2009, 01:42 PM
Dave_Darling   Only one #15 per side. It goes between the mount ...   Oct 2 2009, 11:01 PM
stephenaki   Only one #15 per side. It goes between the mount...   Oct 3 2009, 01:25 PM
stephenaki   Well, today didn't quite go as planned, I got ...   Oct 4 2009, 09:45 AM
stephenaki   IT'S ALIVE!!!! Well, kinda, f...   Oct 10 2009, 12:10 PM
stephenaki   So, I've evidently I have bronchitis, great. ...   Oct 15 2009, 11:51 AM
stephenaki   OK, so today was a rather dismal day in Germany, c...   Oct 17 2009, 12:57 PM
hcdmueller   Is your pulley for the cooling flap cable torqued ...   Oct 17 2009, 01:51 PM
stephenaki   Is your pulley for the cooling flap cable torqued...   Oct 17 2009, 02:07 PM
stephenaki   OK, after a slow start this morning, I watched Mon...   Oct 18 2009, 10:52 AM
ILM914   just took my impeller hub off, if I hadn't put...   Oct 18 2009, 06:20 PM
stephenaki   just took my impeller hub off, if I hadn't pu...   Oct 19 2009, 01:29 AM
stephenaki   So what does one learn when they head out at 0645 ...   Oct 19 2009, 01:56 AM
Gint   1. oil tampon suggestions? Anyone ever rig someth...   Oct 19 2009, 08:37 AM
stephenaki   1. oil tampon suggestions? Anyone ever rig somet...   Oct 19 2009, 11:30 PM
stephenaki   Well, after a long Thanksgiving and some other thi...   Dec 19 2009, 10:24 AM
stephenaki   Well, the weather was warm enough for me to tackle...   Dec 31 2009, 08:14 AM
stephenaki   So, it's been snowing here since last Friday a...   Jan 12 2010, 01:15 AM
stephenaki   OK, phase 2 in this money pit and I need some help...   Jan 23 2010, 04:20 AM
Racer Chris   I have a 1.7 machined for a 2.0; how much be...   Jan 23 2010, 05:58 AM
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