Engine Out: Finally Starting the Overhaul

Today we finally started the engine overhaul properly.

We got the car into the workshop, up on jacks, and started stripping it down so we could pull the engine. I have been looking forward to this. The car has had plenty of work already, but this is where it gets serious.

We started by removing the front end, which went surprisingly smoothly. With that off, we moved to the lock carrier and started freeing everything up to get proper access to the engine.

Then the rust reminded us who was in charge. Most of the bolts holding the lock carrier and the parts around it were too crusty to survive removal. Several snapped, but some of those parts are being replaced anyway.

The AC condenser was in bad shape too. That is the big radiator-looking unit with the fins at the front, and this one had clearly had enough. They are not expensive, so replacing it now makes sense. Plenty of its bolts were corroded and snapped as well, which matters less when the part is going in the bin. Two of the AC lines also broke while we were removing them. They were completely crusty, so it was only a matter of time. Annoying, but better now than later.

With the front end out of the way we could start disconnecting everything else: hoses, wiring, connectors, all the usual things that come off before an engine can leave the car. The electrical side was straightforward. Most of the harness stays with the engine, so separating it was easier than expected. This engine has been decent to work on so far.

Once the hoses and wiring were off, we moved to the rest of the drivetrain: the driveshafts from the gearbox, the dogbone mount, and the last few things holding it in place. Then we could hook the engine to the hoist. One problem: we only had one lifting point installed. The right lifting bracket had been removed at some point. It sits next to the PCV area and doubles as a mounting point for the engine cover. My guess is that we left it off when we did the intake manifold and injectors, since I never use the engine cover. That made the lift more awkward than it should have been, but we got it done. And the engine was out.

With it hanging we drained more coolant before setting it down. There is always a bit more in there than you think.

With the engine out we got a proper look at the empty bay. It is a strange sight, and it makes the project feel real. No turning back now.

One thing I am curious about now is the oil cap extension on top of the valve cover. The car originally had an engine cover, so there is an extension fitted to bring the oil cap higher. I have read it is glued in, which should mean heat will get it off. With the engine on the bench, this is the time to deal with it.

Small thing, but worth sorting while everything is apart.

Workshop days are better with something warm to drink.

Rust, snapped bolts and broken AC lines aside, the engine removal went well. No real nightmare moments, and a smoother job than I expected. Tomorrow we start disassembling the engine and checking its condition properly. That should tell me what else needs ordering and how deep this overhaul goes. I would not be surprised if the cylinders need attention. We'll see. More soon.