Chapter Two: Engine Removal and Rebuild: With Extra Swapage
This is where the actual week starts. Sat Sept. 13, 2008, the car was rolled into the garage and the work started. First things first, gotta get rid of that pesky bumper, headlights, bumper support, and hood.
Of course I had to break a bolt
You like that fmic placement?
After removing everything possible from in front of or around the engine, it was time to focus on removing the transmission, transfer case, half shafts, and of course the rear end, since I was on the business of drive line removal, and I needed to swap rear ends anyways I decided to do it all in one pump instead of bouncing back and forth from drive line to engine and back. The exhaust system was also removed during this.
Can we say rear output seal leak?
After all that was good and removed I then finished removing all electrical, vacuum, and fuel related connections from the intake manifold, head, and engine block, then it was time to hook up and hoist it out.
Then it was rebuild time, but first the tear down and pre-inspection. From the tear down and pre-inspection I learned that I will forever run mobil 1 full synthetic. I had zero sludge or build-up in my head, bottom end, and oil pan. Well on to the pictures.
Then I did forget to take any pictures of the actual rebuild process. But I honed it, used new pistons and rings, new clevite bearings, ARP Main studs, ARP head studs, all new seals, balance shaft elimination, and installed a rebuilt head. Other things that I did was painted the intake manifold, TB, elbow, valve cover, fuel rail, and BOV flat black. Did a FIAV elimination and vacuum reduction. I also removed the intake manifold support bracket, and the AC compressor bracket since the engine was out. I only have a picture of the assembled product.
From here on out it was all just the opposite of removal. But with a few snags here and there. But in the end it all ran, got the idle and timing adjusted, got 100 miles under the belt and blew the head gasket. So now I'm just awaiting to fix that. Then this project will be golden. Now solely for some entertainment.
Clutch alignment without a clutch alignment tool courtesy of JgGravy:
I think this fuel rail is of oriental origins:
Like I said, zero sludge:
My secondary mechanic. She provided at least a good 10 hours of assistance:
So to recap the work performed:
Auto to Manual conversion
Engine rebuild and swap
Drive line swap
Exhaust swap
Upgraded to s16g with tubular manifold
Blacked out engine bay
Vacuum line reduction
Wire tuck to include cruise control placement and throttle cable tuck
Hood pin install
Pedal swap x2
Fuel pump swap
Brake caliper swap all around
Front hubs swapped
Front right control arm swapped
Ecu, radio, gauge cluster, wire clean up, and after market gauge install
I think that's it.
Also, thanks goes to Schiedes for loaning me the engine stand, JgGravy for the assistance, and MAP for the parts in a quick and cost effective manner, they are highly recommended by myself.
Now for the next project. Fixing my head gasket, then installing my new misimoto G line intercooler.
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