Intake off , found I did not tighten the passenger side valve cover bolts correctly.

• go the coil packs bolted down that was 45 minutes of frustration I am really starting to hate SAI, sad thing is the lower bolts are easy the top 2 not so much
• Plug wires routed
• Various hoses etc connected
• AC compressor back on
• Throttle cables connected

Tomorrow after a dentist appt :

• review upper engine cable and hose runs
• Torque upper intake
• Torque A/C compressor bolts
• Torque Spark plugs and install cables
• Install secondary air
• Install exhaust
• Oil & filter change
• Install and double check all cooling system hoses
• Install alternator and battery
• Water and prestone flush into the cooling system
• And start with luck -I have a few ex job things to take care of start might be Tuesday

 

Sounds good. Keep a fire extinguisher handy for your first start after a rebuild. Spray from underneath up, not from top down, if needed.

Best to have a 2nd person away from the vehicle, but on the ground low, looking up at cats for any sign of red/orange/purple glowing during the initial breakin. Also looking for any leaks such as oil, fuel, brake fluid, power steering fluid, or coolant.

20 minutes of being diligent can really up your safety factor during that break-in.

 

Why spray from bottom up? Just curious. On first take that’s counterintuitive.

 

@Brandon318

A couple of reasons I can think of

• that fire extinguisher powder will get everywhere if you go from on top and then you have a complete engine steam clean even for a small fire
• Any fire would come up from the exhaust system, where contaminants can get heated
• The cats are really the problem, if you get enough internal contamination those will glow visibly red in the daylight and that can cause a fire

 

Less work that expected a few other things interfered, but a good short afternoons work.

• Less 2 hoses and IAC (big aluminum canister on top of the Intake) the left side is complete
• 1st oil change done and there was clear water from the pre disassembly cooling system flush in the oil not much maybe a 35mm film canisters worth but some

Just the right side to do

• torque spark plugs
• exhaust
• secondary air bits
• Cooling system fill
• Alternator

Thinking happy thoughts and less rain, 4 deg C and heavy rain the last hour gets right into your bones

On to Pictures


Start of the day

Exhaust gaskets ready to go

End of day right side

End of day left side

rain, I missed getting as shot of the lets see if he has an ark downpour minutes before

 

I want pizza now. Good work.

 

Beats me!






Kidding aside, the #1 reason to spray from below angling up (e.g. lying on the ground looking up at an angle, not directly underneath of course) is to avoid opening the hood.

Murphy's Law is that you won't get the fire until you close the hood, thinking that all is well. Well... don't open the hood back up if you get an engine fire! Simply spray in from the underside.

 

Man there is always something 2 of the right side exhaust manifold bolts will not go in.

Exhaust manifold back off
Chase a bolt and threads slowly work the bolt in with a bit on engine oil - success
Then dropped the damm spacer, when I took the bolt out and it did not hit the ground

Lunch 1st then the great spacer hunt

 

The day from hell 7 hours and the passenger side exhaust manifold is still not on.

Everything started so well, no rain got the plugs torqued ignition wires run, then doom struck :

• The manifold drops in without issue, but the rear 3 bolts will not line up 2 upper far lower
• Threads appeared to be getting damaged so drive 45 minutes (round trip) to rent a thread chaser set
• Get everything cleaned up drop a spacer, one thud and nothing
• 2 hours later I found it, it had the frame rail roll between 2 cables and ended up about where the cat is found with my inspection cameras. I was concerned it had lodged a somewhere bad.
• More fiddling and cursing the bolt holes will not line up, got to love chopsticks as a bolt substitute

After a lot of fiddling it appears I need to pull the Y pipe down, so tomorrow :

• Undo the driver side y pipe nuts
• Suck that thing down with a couple of cargo straps
• Get the damm manifold in
• call a possible employer in the afternoon

 

That sucks Richard, I hope tomorrow goes better.