Well here we go noticed a bit of an oil leak over the weekend oil was dripping down onto my exhaust headers the odd puff of white smoke from under the bonnet.
I had just replaced the o ring on my power steering tank and thought it was just spilt hydraulic fluid burning off.

took the car off the road just to be safe and well no car meant plenty of drink.

Any way decided to take a run down to cars n stuff and throw her up on the ramps to get a look.

heading down probably just over a mile and noticed an awful lot of smoke behind the car well I was half way there and had to stop at a roundabout just as I did flames flashed up through my drivers side small vent.

The oil was on fire I floored it to blow the flames out but every time I backed off back they came worse than ever.

Made it to Normans place and jumped out opening the bonnet and grabbing my fire extinguisher.

I very quickly extinguished the fire and had a look to see what had caused the oil leak.

Turns out the there was a rocker cover bolt sheared off directly above the manifold.

So this left me with the need to remove the sheared bolt.


Today mark and I got stuck into it

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0015.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0021.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0022.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0029.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0033.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0034.jpg

USE THE FORCE

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0037.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0027.jpg

So all disconnected

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0041.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0042.jpg

A few spectators turned up to lend their support

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0047.jpg

OUT IT CAME

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0048.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0050.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0049.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0051.jpg

Check out the lightened flywheel
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0052.jpg

Thats enough for 1 day

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0053.jpg

So now the engine is out im going to take advantage and carry out some maintenance.

Gaskets and seals to be replaced going to get the clutch relined ( to cope with the launch control )

Throttle body water way mod

paint inlet manifold

trying to find clear cam covers

timing belt replacement

and just a general clean up and check over

holy **** mate long as your ok and no real damage to you baby hope it sorted soon:thumb:

Thank feck u had an extinguisher m8.

I think Scubbay's 2.1 block would fit that big space:lol1:

yeah rab at least ya caught it before any serious damage! get her back on the road quick tho :)

lucky lucky escape big man..:thumb: :thumb: :thumb: :thumb: no serious problems i hope..



and as your leaving that engine sitting about. just move it over a bit towards the door incase im passing:luvlove:

fabio

No real damage melted the element in my hks mushroom filter but it has given me the incentive to do a wee bit of tinkering .............. it had to bloody snow today didnt it

mate ur wer so lucky, dorman lost a cossie you and i once knew like this.

thank god.

Looks like you need a rear crank seal there too. I have timing belts at the right money if your this way.

Whoo man that could have been alot worse, youve done the right thing now though, get her back out soon.

John

that powder makes a fair mess, but it done the job for ya, someone looking down on ya lad

DAY 2

Well finished work early and straight back to the problem in hand

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0058.jpg

The offending sheared bolt
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0067.jpg

Removed good old easy outs
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0068.jpg

Now for that crank seal
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0069.jpg

so so sexy
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0070.jpg

clutch n flywheel removed
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0071.jpg

Cam belt covers off
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0072.jpg

ROBO MARK
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0073.jpg

Aircon compressor removed and away to the bin
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0074.jpg

Altenator off
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0075.jpg

Im starting to think its going to be a week or 4 before its all back together having gone this far im thinking of changing the head gaskets too

Inlet manifold removal
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0076.jpg

Enough for 1 day

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0078.jpg

still got a long way to go and im really enjoying learning more about what makes the car tick

love that one with mark duken over the top.

mate - keep her at it, txt if ya need a hand or break!

fair play 2 ya rab!!

front crank seal in the oilpump seems to be leaking there too dude.

Yeah planning on changing all the seals and gaskets

Day 3

Work kinda got in the way today but managed to get a wee bit more done

Stripped down the inlet manifold
http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0041-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0040-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0042-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0038-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0046-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0052-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0053-1.jpg

Going to take some time now to clean all the ancillaries, paint the manifold, wrap the exhaust headers and down pipe and remove the sump and oil cooler want to get all these bits out of the way before starting on changing the seals and head gaskets

your very lucky there mate,
but now lets you get some things minted up ;) and painted.

Will look pretty again when its finished im sure ;)

engine porn...........................dont you just love it:luxhello: :luxhello: :luxhello: :luxhello: :luxhello: :luxhello: :luxhello: :luxhello: :luxhello: :luxhello:


fabio

Good time to slip that 2.1 forged shortblock in there now!!!
will even part ex your old unit

Day 4

Just a bit of degreasing today

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0041-2.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0045-2.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0048-2.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0052-2.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0053-2.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0054.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0055-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0058-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0059.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0062-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0063-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0064-1.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/engine%20out/DSCI0065-1.jpg

Next will be to split the heads but first I need to find out about removing the timing belt correctly

good work there Rob. If u feel an extra pair of hands would help give me a shout.

Day 5 ( work kinda got in the way this week )

So finally got a chance to get a bit more done
Got the engine onto a stand
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0071.jpg

Off with the sump
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0072.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0068.jpg

Then the timing belt and cam pulleys
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0076.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0074.jpg

Cam shafts out
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0075.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0077.jpg

then off with the heads
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0081.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0080.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0082.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0084.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0086.jpg

Not so big now lol
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0083.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0078.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0088.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0090.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0092.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0093.jpg

so lots more cleaning this weekend
And alot of seals and gaskets to be bought

getting on well there mate :notworthy

fair play for tactling that

ur new years res not going to well mate ( smoking ) :)

:lol1: aye howz the wrk going the now? rab will you be on da rd for rolling day next month ive discovered my old girl is using! oil canny see any leaks or decide wots going on shes due for the ramp monday night to get a m.o.t check going through <fingers> crossed! today week...

well started to buy a few of the bits needed to put it all back together

Graham goode racing timing belt

head gaskets

head bolts

rocker cover gaskets

need to get crank seals and im after a new set of timing belt covers as mine have a few cracks in them.
If anyone knows where I can get the clear covers please let me know

Done a bit more today
Washed down alot more bits and bobs then decided to take of the oil pump to get at the crank seal.
This is where it all went a wee bit pear shaped the sprocket just wouldnt come off a wee bit more leverage and ..... yeah bits broke off it also managed to do a bit of damage to the oil pump brawn over brains im afraid.

Has anybody out there got an oil pump sprocket kicking about the toothed one that sits ( very snugly ) on the crank shaft.
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0083.jpg

Im looking at an uprated oil pump on fleabay but can't seem to find the sprocket anywhere.

Planning to start putting everything back together mid week after ive checked the main bearings

Dont buy the "uprated" crap for sale anywhere as their a joke. Cost me a 10 grand engine to discover a 60p spring was the "uprate"
What a load of bollocks#.
I have a genuine Subaru pump here with oil seal.
Learn from my mistakes. Its free experience.
Im tryin to help you guys here

ps I have the sproket too

Done a bit more today
Washed down alot more bits and bobs then decided to take of the oil pump to get at the crank seal.
This is where it all went a wee bit pear shaped the sprocket just wouldnt come off a wee bit more leverage and ..... yeah bits broke off it also managed to do a bit of damage to the oil pump brawn over brains im afraid.

Has anybody out there got an oil pump sprocket kicking about the toothed one that sits ( very snugly ) on the crank shaft.
http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0083.jpg (http://i148.photobucket.com/albums/s31/ulsterscooby/short%20block/DSCI0083.jpg)

Im looking at an uprated oil pump on fleabay but can't seem to find the sprocket anywhere.

Planning to start putting everything back together mid week after ive checked the main bearings

Been there done that :(

A puller is the only way to do it safely.

Back at it again today

Oil pump removed

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0040.jpg

Got a bit of a scare when I noticed this
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0041.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0043.jpg
The crank had been at one stage eating into the block once I stopped shaking I noticed that the gasket / sealant was sitting proud of the damage so it is an old wound.
I knew the engine had been rebuilt at the end of 2005 so im assuming this was damaged caused before the rebuild.

Panic over I continued with my tinkering

Down pipe heat wrapped

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0048.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0049.jpg

Inlet manifold painted

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0047.jpg

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0054.jpg

sump cleaned and painted
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0057.jpg

Fuel lines painted
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0046.jpg
Heads cleaned and inspected
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0062.jpg

As she sits now engine spread out over about 20 foot of work bench lol

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/DSCI0063.jpg

Bought a few bits and bobs

Braided turbo oil feed pipe and clutch pipe

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/89_2.jpg
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/d580_2.jpg

New front brake pads

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/d239_2.jpg

water pump
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/107341007-1.jpg

magnetic sump plug
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/71b1_2.jpg

Graham goode racing timing belt

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/83_11.jpg

Flat wiper blades

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/2d5f_2.jpg

Head gaskets and bolts
http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/f9c9_2.jpg

And just couldnt resist a JDM style number plate

http://i148.photobucket.com/albums/s31/ulsterscooby/more%20cleaning%20and%20prep/Plate_EJ20.jpg

Looking to start the rebuild next weekend but before then its time to turn my attention to the car its self some work in and around the engine bay just to tidy things up and also working on a bit of ICE