Project: my first 20v

[Afterthought]

This will be staying NA.

10-4 .
Let me know if you want a bag o snakes for it . I’m about to pull another 7A that has one in the next 24 hours

[DE80q]

Looks like it’s all there. Good thing he was organized. I had to repair my euro front bumper too. You might consider relaying those lights since you’ll be integrating new connectors anyway.

Oh, and let me know if you find a source for the bumper grills. I’m missing one on my bumper.

IF I can find them, I will let you know.

This will be staying NA.

10-4 .
Let me know if you want a bag o snakes for it . I’m about to pull another 7A that has one in the next 24 hours

I should be getting one with the engine I'm picking up, but if that falls through, I will surly hit you up. What I really need to find is a stock exhaust. The one on the car is literally falling apart.

[DE80q]

Well family vacation is over. Had a good week with my wife and daughter at the beach. Time to get some work done...

Started today. I've never removed a 2 piece bumper, so that took a little extra time. Not to mention I'm spoiled with my sedan having all the plastic removed and wiring tucked out of the way...


Couple small things I found that will need to be addressed. One is the wiring for the dizzy needs to be repaired. One wire already has tape on it, and another has a split in the insulator. Another is the crankcase breather system need completely redone. The rubber hose is pretty well gone, and the pipes are clogged.


There is also this wiring fix... There is a little green wire soldered onto the back of the MFTS connector. It runs the whole way into the cabin, so I guess it must have worked...


Also, the alternator is completely locked up, so will need to replace that as well.

[PRY4SNO]

Boy oh boy, that's crusty. Feel lucky we don't use much (if any) salt around here. I bet you're going to find some Easter eggs on this one as you go along.

[DE80q]

Hit a little financial snafu, so things are moving a little slower than I wanted. So, instead of going and picking up my engine, I'm cleaning things up, I wish I would have taken before pics

Here is the carpet. The PO said he thought it might be trash, but I pressure washed it, and it came out pretty good. Unfortunately the rubber backing is trashed. It's all cracked up and peeling off.


Ok, so this car has 203k on the clock. I honestly believe the valve cover may have had the original gasket on it. Still have the OEM part #s and still kind of flexible.

This is after multiple cleanings at work with a mildly caustic soap, and the 180°F pressure washer. Follow that with a strong solvent cleaning and a good blasting... Now ready for powder coating.



Then there is the intake manifold. This thing was caked horribly on the inside with oil. The breather system in the car was pretty well non-existent by the time I got it, so I can only assume it was breathing in quite a lot of oil vapor for a long time before the timing belt popped...



The throttle body was pretty nasty as well. It was pretty well completely black when I started. This just took a trip into the parts wash tank. After about 10min of scrubbing, and another couple of mins blowing off all the excess solvent, it looks like this



All in all I'm happy with how these came out. Hopefully have more to report soon. I'm still waiting for Audibits to ship me a bumper. He said he isn't happy with the one he showed/sold me, so is trying to find a better one.

[sayoda]

Parts are cleaning up nicely!

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[Grillage]

Looking good!

[DE80q]

Progress is slow, but at least it's something. I need to get my truck fixed(the financial snafu) so I can head up to CT and get my engine.

[DE80q]

Got some time this morning to work on this. Decided I should probably check out the trunk rust. Wasn't as bad as I expected. The PS has a small hole, but the DS seems to still be solid.


I figured I should probably check the condition of the tank while I'm back here. That was fun... Someone must have lost the hardware for the rear 3 bolts that hold the trunk cover, so they just rammed in some regular bolts... After finally removing the tank cover, I was violently smacked in the face by the smell of varnished fuel. Not good I would say, but at least this looked clean enough...


Pulled the wiring connector for the sender and found it to be wet.


Pressed on with a brass drift to pop the sender ring off. Came off easily, they had fun getting the sender out of its seal. When I finally got it out, I was greated by this!


This damn tank if completly full! Full of 4 year old fuel! On one hand it's good, as it should have stayed off the corrosion, on the other hand, now I have to get it out of there! as of what is in the tank was giving me a massive headache, I called it a day and put the sender and ring back on. I'll figure out a way to get that stuff out of the tank, and then how to dispose of it. Should be interesting, hopefully the pump itself still works.

[DE80q]

Today I drained nearly 14 gallons of old nasty fuel from the tank. At this point I couldn't find anything deep enough for the siphon pump to suck out.


That was most of it... And don't worry, that wasn't a water container I used. The amount of crap that got sucked up through the siphon was amazing. I used an old kerosene siphon pump, so was roughly a 5/8" hose.

Here are a couple shots inside the tank. Not pretty, but not a total rust drum either!



I also need to look into a tiny little wire for the sender. The one that attaches to the swing arm is completely gone! I was however able to clean that up and make the arm move freely again, so that was my win for the day... Once I find some 22ga(?) Gasoline safe wire, I will be pulling that apart again, to replace the missing wire. Fun fun...

Oh, and does anyone know the part # for the sender seal? Those one on top of the tank. Mine is split in a couple spots, and 1/2 of the lip that goes into the tank has turned to goo...

[Afterthought]

Re: the seal for fuel sender , the O-ring should be 113 919 131 A

[DE80q]

This one doesn't use an oring. It's more like a rubber flange gasket. Thanks though.

[DE80q]

Decided I would make up a lock ring tool instead of buying one. About an hour of work, and a bunch of scrap stuff later I have a very useful tool. I never liked the idea of beating on these rings with a brass drift, as I tend to hit everything else around it as well...



Now to find the pump tool...

[PRY4SNO]

Nice tool. That's really slick.

Yeah. Um, brass drift. Proper tool for the job, what with no sparks and all. But I just use a flat screw driver lol. Luckily I've only had to push hard on most, and lightly tap with a rubber mallet on one or two.

[DE80q]

Spent half the weekend in the garage. The old bottom end it out! Took longer than I expected, but that's what I get for doing it by myself. It's been a long time since I took out an engine, and honestly forgot a lot of it. Hell, I couldn't remember how to get the radiator and condenser out, so I worked around it. At least it's out now, so I'll be cleaning a lot of things and getting ready to install the next 7A. I'll be working on getting the radiator and condenser out over this week as well.

As always, here are the pics of it out...



Oh yeah, as you can see in the hanging pic, I had to make some M11 eye bolts. I did that by cutting down a couple old head bolts and welding on some pieces of tubing.

Also, the scary part of the whole thing was the amount of rust falling off the subframe... I filled a standard household dust pan with what fell off while getting the engine out. I may need to find some better subframes...

[mr_aj_johnson]

I can ship you some rust free west coast parts, or you can use those rusty ones as templates for a tube subframe

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[DE80q]

I can ship you some rust free west coast parts, or you can use those rusty ones as templates for a tube subframe

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I may have to take you up on that AJ. Unless I can find a descentley clean one around here.

[mr_aj_johnson]

I have a b3 20v in the driveway complete with rear sway bar and all

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[DE80q]

Hmmm... Very tempting. I'll text you later.

[DE80q]

crappy pic of the things picked up in CT this weekend.


I'll go through it tommorow, and take better pics before I start to assemble things again...

[DE80q]

I had plans to pull the engine apart for a complete reseal this weekend. All my parts showed up today, and I was kind of excited. This was until I pulled out the timing belt rockauto sent me. The belt they sent was 1/2" too wide, and way too long! I even made sure the part# was correct... I filed a claim with them, and should have another belt next week. Hopefully this one shows up correct. Not sure if I want to pull the engine apart without having the timing belt on hand though.

[mr_aj_johnson]

Pull it apart. Reassembling will take longer than you think

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[PRY4SNO]

^^^ Agreed.

Also, if/when you find things inside that ought to be replaced... while you're in there, you'll have less down time waiting for parts.

[DE80q]

Yeah, I'm going to take a nap, then work on this later.

In other news, I managed to get the broken bolts out of the lower heat shield. Then figured out how it mounts up. Kind of a PITA, but will be worth it for the OEM looks and function. Now I need to figure out what is supposed to bolt to the top of the heat shield.

[DE80q]

Well that was easy to figure out! Turns out there are some very distinct differences between the early and late style intake manifold!


Looks like I will need to machine, drill and tap the late style intake to mount the heat shield. I didn't realize that was how it was held on! I'm glad Tim threw in an early intake for me to compare with.

Also, I welded up the outlet flange on the BOS. There wasn't much left of it, and it was mild steel. So I made short work of it with the mig welder. Then I ground, filed, and stoned it to make sure it was flat and in line with what was originally there.


Not perfect, but should work well. At least there is something of a flange there now.