So the engine drop happened this weekend gone!!
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What a crazy weekend it was.
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Before I start I just want to thank Simba, Peter
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(SBITS) and David
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(Draven).
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Special thanks to David for all his pms and knowledge of wealth
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So where to begin.
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The plan from Friday to Sunday was to get the chargecooler system, rear clip and everything else I might need off the sonic shadow.
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This all flopped when the garage was busy and I didnt get a ramp until 5pm on Saturday.
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Couldnt really complain since they have a business to run and Im just grateful for power tools and a ramp.
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Anyway, with a brand new workshop I thought the conversion would be nice and easy but it wasnt.
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Their new mechanic is a messy guy
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Tools were all over the place, all the tools were dirty and before I could even start I had to clean up the workshop area and sort out some of the tools
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Finally by 6pm I had the car up in the air.
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My game plan was to remove the chargecooler system including engine rad and then move onto the rear clip.
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Progress was sloooooow.
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So many videos, pics to make sure I could then refit the system back in.
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So start with the essentials:
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Moving onto the chargecooler strip down:
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After removing all the covers I found 2 issues under the car.
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Firstly the routing of the passenger side of the pipe work near the steering rack was shoved into the shell and this was the outcome:
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Shock horror! The chargecooler system ran for 3 months, I then crashed the car and it sat there for a year.
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Any advice on this would be great.
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Im not sure I can reuse the pipe and really dont want to add another join.
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Best bet might be to just get new pipe work.
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Where from though?
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The second problem I found under the car was the rear cancer bars are missing???? Really not happy about this!!!
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While I removing all the pipe work I did have a good look and tried to think alternatives.
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But this is for another thread.
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The rest of the system came off nice and easy.
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Simply routing the pipe work back through after removing the cc rad, brackets and also the engine radiator.
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Time for dinner:
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So it took me up 6 hours to get this far
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Now everything from the front moving to the back was undone and I could start on the engine bay.
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I cleaned up the workshop, cleared all the spills and set up for Sunday morning start.
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Progress up to this point was very slow.
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I didnt rush into starting and wanted to document the CC properly.
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I was expecting my mates to show up and help for Sunday but they thought sex was more important and let me down
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Roll on Sunday and the one man army.
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My plan was to remove the chargecooler and then use this epic guide for removal.
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I moved the whole thing into a word doc, sorted everything out and printed it.
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.64 pages!!!
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Heres the guide you need people:
Removal Guide
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So Sunday I woke up, showered, had breakfast and went to the workshop.
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From this point onwards I removed the CC core and followed the guide religiously!!!
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Starting point:
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Ok, lets discuss labelling.
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How much time does this add to a job.
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.HOURS!!!! I masked up every pipe/wire, wrote down where it goes and all bolts went into a bag with description including what page of the guide I am on.
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This way if I reverse the process, I can see from the guide what I did.
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Thats the plan anyway.
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The guide is amazing.
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It tells you exactly how to unclip things and I was beginning to enjoy myself.
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It was painfully slow and I was getting stressed out.
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However if I had help, then how would I know where it all goes? In the end I think it was a Godsend that I did the whole top end strip down without anyone there.
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The only wiring plug I couldnt remove from the whole build was this one:
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I decided to just cut the cable tie that was there, labelled the 2 pipes going to the charcoal canister and then just removed the charcoal canister.
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At this point I was starting to realise that I was labelling stuff I might not even take to the new car
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Anyway, I was close to finishing off unbuttoning everything from the top of the engine.
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I wanted to make sure I got the CC relay bit correct:
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Finally with everything undone, I raised the car and started attacking the underneath.
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HOW AMAZING ARE POWER TOOLS WITH THE CAR UP IN THE AIR.
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Within no time, the driveshafts were out, all suspension bits removed
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(I left the driveshafts in the spindle while I worked on everything else)
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Next attack the exhaust.
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When working on your drive, you can jack the car up but never high enough to get a breaker bar on there.
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With the car in the air, breaker bar and the exhaust bolts were off:
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So it was around 7pm now and the guide said
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This is a good time to get a buddy to help! and finally my mates show up
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I have friends
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All day Im calling my people begging them to show up and in the space of 30 minutes, three of them show up.
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Thanks guys
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Getting the exhaust off was nice and easy with more than 1 pair of hands and we moved straight onto the subframe.
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This where I had my first bolt snap
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(ARB one):
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Now my mate works on gas turbines all day so all he wanted to do was start cutting xxxx out!!!! He grabbed the angle grinder and started cutting the ARB.
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While he was man handling the power tools I decided to just prise the ARB out of the way, saving us the trouble with cutting.
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Impact gun on the nuts and subframe dropped out
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While we were under the car the front engine mount was removed.
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At this point nothing should have been attached but somehow I had missed the clutch slave pipe.
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I tried to remove the hose by undoing it but I couldnt and with time really running out, I decided to chop the hose and address this later.
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Next job.
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.DROP ENGINE!!!!!
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Got the crane in position and attached it to the mounting brackets
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(thanks again David aka Draven for all your advice).
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I bought a dolly from machine mart and also used an old tyre and block of wood to balance the engine.
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On the fourth attempt the engine was perfectly balanced:
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Yes people I did it!!!!
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By this time it was late, everyone needed to go and I needed to get the car down, all parts put away in the storage unit
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(including car) and clean the workshop.
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The problem was with all the suspension missing, how were we going to move the car into the neighbouring unit???
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Ratchet straps people:
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The look on mates faces was we attempted this:
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Car
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rollable:
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All parts and car safely in the storage unit:
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So whats left.
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I didnt have time to remove the fuel tank so I quickly gunned all the nuts off the underneath and kept the plastic tab in place to hold the fuel tank in.
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I need to remove the wiring from the cabin and the unclip the hoses in the engine bay.
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The gear linkage cables need to be removed as well as the rear heat shield thingy.
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Once these items are removed I ready to start on the NA engine drop
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This week I will be popping into the workshop to:
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Clean and paint the subframe
Clean whole engine and touch up some paint.
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Remove engine heat shield and paint again.
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Heat shield is all flaked up and needs some sort of heat resistant paint I think.
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Check the engine out properly for any damage and pipes from hell.
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That was my weekend people.
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After doing all this with the facilities at my disposal I have amazing respect for those who tackle this job on their drive/garage and do it in half the time.
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Amazing stuff
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Roll on Easter weekend!!