Grease Monkey

With the engineering done, I now have a few weeks in which to sort out the teething problems, which in my case means:

1. Oil leak from somewhere major
2. Oil from the gearbox breather
3. Cylinder number 3 running lean
4. Various loose nuts and bolts
5. License plate light

The first two tasks required the engine to be removed, so that was this weekend's task.

Removing the engine wasn't as hard as I thought it would be. The task list is:
1. Remove exhaust
2. Remove throttle bodies
3. Remove fuel lines
4. Disconennect wiring from injectors, alternator, engine earth points, starter motor and crank sensor
5. Remove alternator
6. Remove belt tensioner and belt
7. Remove and drain radiator pipes
8. Detach clutch hose
9. Remove seats and belts
10. Remove centre console
11. Unbolt and remove drive shaft
12. Slightly lift the car with an engine hoist
13. Put a trolley under the engine
14. Remove engine mounts and gearbox mounts
15. Lift car up over engine and slide the engine out from underneath, making sure everything clears and nothing is still attached

Took about 3 hours all up - can take two once you know what you're doing, so I'll expect an improvement next time.

OK, so with the engine out, I then proceeded to remove the starter motor and bellhousing, then the clutch and clutch plate, in order to find the source of the leak. We removed the plate holding the main seal, and saw the problem...

There's a small lip around the main seal which closes up against the gearbox shaft to keep the oil from leaking. And I had it flipped inwards instead of outwards. That's it. I've pumped probably $100 worth of oil onto Frank's floor and the road because I had a seal in backwards. Idiot.

So we put it right, and then moved onto the gearbox.

I now have a new top plate on the gearbox, which has a baffle welded underneath the breather hose in order to stop the oil froth from bubbling up so easily. It will still allow expansion in the air as the gearbox heats up, but should stop the geyser of green oil. I also removed all of the gearbox oil and will replace it again, as I now had no idea how much was in there.

So, with the main seal fixed and the gearbox hopefully done, everything gets done in reverse. I did run out of time though, as I had to go home and cook dinner for 8 people. I dunno, modern man that I am - I can spend the day removing and reinstalling the entire drivetrain from my car, then be home in time to whip up a four course meal for 8 people.

Got nothing done on Sunday, of course. Except the dishes.