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Loose exhaust manifold, part 3

 

Plan-

what I want to do

Since I had the bottom end rebuilt less than 40,000 miles ago, I am not going to be pulling it all apart.  Hopefully the dealer did at least this right.  I am just going to give this thing a good cleaning while the head is out.  Plus I have borrowed a straight edge to see if the block is flat (please, please, please).  I'm amazed at how small the block seems with everything off it.  I finally have a true idea of just how little the displacement is.  Three liters, that's it.

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Project-

what I did

Fortunately the block was good and flat. 

I plugged all the water holes, bolt holes and around the pistons with a heavy marine grade grease to keep particles out of the important places.  A dremel tool and some light abrasive disks is what I used to clean up the block deck.  I will used this to clean up all of my gasket surfaces.  Fortunately the block was good and flat.  I was pleasantly surprised at how easily everything cleaned up.  It looks good with ten years of crud gone off the engine.  I used a degreaser that sprayed with a hard fast stream instead of the foamy kind, it seems to work better. 

With the engine out, it's easy to see the engine bay needs destailed.

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Difficulty-

things that made it hard

1- This was very easy as all I did was clean up the block. 

2- This could have gotten far worse if the deck had been warped.

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Problems-

with the product/install or that came up later

9- During disassembly, I noticed that the crank pulley turned a bit on its own.  It seems that the keyway has gotten wobbled out (loose bolt).  Fortunately the timing belt pulley is ok, or I would be putting another crank in this thing.  Since it's just the accessory belt pulley and damper, I am going to repair this with JB Weld.  I wrapped the new key in wax paper, filled the keyway with JB Weld, and clamped the key in with a hose clamp.  After curing, I removed the key and unwrapped it, and filed the JB Weld smooth.

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Intermission-

on to part 4

There is about 35 square feet of parts that is now out of the car.  I sure hope I don't have any parts left over when I'm done.  Now I'm just waiting for the new head.

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It looks so small

The pulley key is warbled out

Grease to seal the holes

Cleaning the deck

Parts, parts everywhere

 

 

Last updated: Freitag Oktober 21, 2005

Copyright © 1997-2005 Duane Smith

Time

144 hours (5 hours here)

Total costs

$1,683.50 ($45.50 here)

Difficulty

12

3

45678910

Problems

1234

5

678910

Payoffs

See part 7

 

 

Materials & parts

Engine degreaser- $20.00

Brake cleaner- $12.00

Bottom pulley key- $2.50

Stick of JB Weld- $2.50

Piece of wax paper- on hand

Marine grease- $5.00

Rags- on hand

3M abrasive disk- $3.50

Tools

Deck checker bar

Dremel tool

Small head scrub brush

Flat file

Engine stand