Into the new workshop and the Legnum is back on the operating table.

While reassembling the intake, I dropped a fuel rail spacer and it some how ended up down the inside of the timing cover… So the timing covers and crank pulley had to all come back off…

First problem was I couldn’t get the crank pulley off as the bolt was cranked up tight. I have a nifty trick for doing this, I pull a spark plug out and feed a meter of rope into the bore. Then slow spin the crank over till the piston compresses the rope and lock the crank up.

Works every time!

And there is the damn spacer…

I’ll leave the front covers off while I put the intake back together just incase it happens again 😛

Fuel rail back on, no fail so far…

Intake back on.

Lower timing cover back on, just about to put the crank pulley on.

Rope out of the motor and the spark plug and coil back into their normal positions

Air conditioner compressor reinstalled.

I forgot to take some photos of what happened next, but the power steering pump when back in and the lines were reconnected.
Till next time!

Getting closer.

Time to sling it back in the car.

Picked up one of those engine balance beams, but it’s chains were stupidly short, so I had to dig out some rustic chain from a box.

Heave!

Lets do this!

Just need to clear the subframe with the alternator as well as the gearbox.

And it’s hanging!

Till next time.

Time for heat shields! Front all armored up.

Rear heat shields, all 4 pieces of it!

Magically the front timing covers, alternator and some other ends have appeared!

Adding the pipe work back on (this will bite me later….)

Fitting the thermostat housing and cross over pipe.

Finally, the cam cover rubber washers arrived so I could replace the old ones.

I might have lost a few of the bolts during this project…. On go some shiny 304 stainless bolts.

Looks spiffy.

Till next time.

More parts arrived for the Legnum, so it was time to crack on.

New exhaust manifold gaskets.

Still awaiting new manifold nuts, so just a couple of old ones to hold it together for now.

New timing belt tensioner pulley arrived

Started aligning the timing and putting the belt on. I like to use zip ties to keep the belt in place as I go.

All done, several laps of the belt done and the tensioner pin has been pulled.

Looking forward to start buttoning this motor up now and getting it back in the car. Once I have the new manifold nuts and a couple of new copper washers for the banjo bolts on the turbos, they can all go back together. The thermostat hosing is looking like I will need to weld a new fitting on to replace the rusted one, more on that next time.

Time for the water pump.

Old on was pretty worn and leaking.

Pump gooped and bolted.

Timing gears back on. As I was bolting the new timing kit on, I noticed I was missing the new tensioner pulley that bolts to the hydraulic tensioner. Flipped the shed over and emptied all the random boxes but couldn’t find it, so I’ve had to order another one. This will delay this part of the job for another week or two.

With the timing belt stall, time to tackle some other small bits. Brand new plugs.

The coolant bridge pipe and thermostat housing is a mess and leaking, it needs a good cleaning and to find where the leaks are.

I found the source of one of the leaks, along with an old crunchy hose. I’ll have to decided if it’s worth reaming the old fitting out and welding an alloy barb fitting on.

Quick brake clean and a scrub of the lower intake manifold before plonking it back on.

Time to open another box of goodies to add to the motor.

Camshaft seals being fitted.

There front turbo was coated in grease and shit since the front cam cover gaskets were leaking, so I removed the front turbo and started cleaning the block, the oil filter mount and turbo drain

Some brake cleaner and a nylon brush to loosen all the shit up.

Looking better!

Clean Turbos!

Yeah…. I got a brake cleaner addiction >.>

Time for the cam covers. Spark plug seals and perimeter seal.

And fitted.

Picked up some ARP studs and kicked off the rebuild.

Started cleaning the pistons and deck

Studs in.

Head gasket on.

Unwrapped the heads and began preparing to slap them on.

Head on, ARP washers and nuts fitted, just needs torqued.

Time for the next side.

Cleaned and studs in

Gasket on.

Head on and washers/nuts fitted.

Dug out the old torque wrench and torqued the studs to spec.