Page 5 - Engine Replacement (newest update to oldest) It makes more sense if you read from the bottom up.
5/25/2006: More rocker asesmbly drama
5/11/2006: Rocker shaft bolt was loose - most likely source of knocking sound.
Close-ups of the hydraulic lash adjuster.
2/22/2006: Check Engine Light won't go out after multiple reset attempts. Will be buying an OBDII code scanner to troubleshoot this. Also need to reassemble the bumper and headlights. No leaks though! :)
Green connectors for the OBD troubleshooting.
2/21/2006: Finished up connecting everything. Popped iin a new Modine radiator, cleaned up the coolant overflow tank and took a quick peek in the valve train before bolting on the oil filler tube. Got a change to fire the engine up, but then was so exhausted at 2:30am that I called it a night.
2/19/2006: Finally,the new engine is in the car. Took 3 hours of wrestling by myself to line up the rear studs, engine mounts, and the dowel pins to make it go in.
And now I understand why the pitching stopper on the transmission has to come off - I had a lot of trouble aligning the motor without lifting the transmission. At one point I raised the transmission so much that I pushed the clutch band adjustment nut into the body tunnel. Duh.
And this nut - the royal pain of them all....left lower engine to transmission requires the craziest combination of swivels and 3/8" drive extensions to clear the axle and get a decent torque.
This is combination of extensions and u-joints on the 3/8" drive under the intake manifold needed to tighten and torque the drive plate bolts to the torque converter.
2/18/2006: After over two weeks, the intake manifold is back on the engine.
2/17/2006: Engine builder sent 37/64 drill bit and tap to add the EGR hole on the left head.
The hole dumps right into the exhaust port just next to the valve. In fact, as you drill through, you have to be careful since once through the aluminum, the bit easily runs into the valve stem behind it. Hopefully now the intake manifold can go on without any more problems.
2/11/2006: No threads in the new block for the lower EGR pipe connection.
2/10/2006: A photo of the backside of the crank pulley. Not sure if the slot has been gouged out. Comparison with a new pulley shows.....it is messed up! $146!
2/9/2006: Finally got around to installing the rear oil seal sent by the rebuilder overnight. It was a little bit of a hassle trying to seat correctly. But it is in now - flush with the block surface (maybe just a smidge under the chamfer).
2/4/2006: Project came to a grinding halt. Rear oil seal is not installed. *snarl*.
Photo of the garage as I move the engines around in preparation to move the trailer out and move the car back in.
2/2/2006: Been cleaning the intake manifold in preparation for migrating everything over to the new longblock.
Photos below are a comparison of the original motor with the plastic plate and the rebuilt motor's aluminum plate.
1/29/2006: The grim task of cleaning up the engine bay while the motor is out. Unbelievable amount of oil crud on the crossmember.
1/28/2006: Intake manifold removal. Engine mounts.
Hmmm....where does this thing go?
1/28/2006: Motor finally out of the car. Time to start swapping the intake manifold and accessories over!
Close up of oil leaking from passenger side head (rear).
1/26/2006: Teardown of the engine underway. Only have the mounting bolts and drive plate bolts left to disconnect. Bummer that I need a new radiator.
Reference photo of starter contacts. Might change them since I have it out. This is what they look like at 140K miles after a change at 89K miles (right photo)
1/20/2006: Rebuilt engine delivered! Replacement gasket set that came with the engine