Today Ion and I tackled the IMS bearing replacement. All IMS bearing extraction tools belong to N0tt0n, who graciously let me borrow them. Thank you thank you thank you!

Here is the sequence of steps. The removal was pretty straightforward.

http://i983.photobucket.com/albums/a...psb6k18l8h.jpg
http://i983.photobucket.com/albums/a...psxifzb4ng.jpg
http://i983.photobucket.com/albums/a...psebjgmykg.jpg

The original IMS bearing was in great shape. No play at all. It seems to have been lubricated by engine oil, as there was oil inside the IMS itself.

http://i983.photobucket.com/albums/a...psriahii90.jpg
http://i983.photobucket.com/albums/a...psakb4abt3.jpg

Here are the kit components being used for this install. The Pelican kit fits both single and double row IMSs, so some parts are not used. The single and double row component zip lock bags were labeled improperly. Not a good sign.

http://i983.photobucket.com/albums/a...psewusdtqc.jpg

Bearing tapped in.

http://i983.photobucket.com/albums/a...psuub0gvvr.jpg

Spacer sleeve added.

http://i983.photobucket.com/albums/a...pszuu49a3r.jpg

Locking ring inserted.

http://i983.photobucket.com/albums/a...psvnlnzh42.jpg

In theory this should have been it. Pretty easy stuff. Unfortunately, that was not the case today. After installing the locking ring, we noticed that it was not sitting deep enough in the IMS groove. It turns out the spacer sleeve was sticking out too far and thus blocking some of the groove where the locking ring should slide in. We tried tapping the bearing farther, but it wouldn't budge. At this point, we started measuring the thickness of the spacer sleeve.

http://i983.photobucket.com/albums/a...pspoq7enaq.jpg
http://i983.photobucket.com/albums/a...psxsafxvgh.jpg

Oh oh! Thanks Pelican. We quickly touched it up with some 200 grit sandpaper, cleaned it, and sure enough, it now sits flush with the edge of the groove. The locking ring finally fit properly too. This cost us an unplanned 2 hours worth of work. Final installation.

http://i983.photobucket.com/albums/a...psa3hxfuyo.jpg

The next step was to complete the crankshaft carrier assembly. To that end, the rods for pistons 4 - 6 had to be installed. Old and new bearings and bolts.

http://i983.photobucket.com/albums/a...psuhaech56.jpg

Aaand done.

http://i983.photobucket.com/albums/a...pshdxp5r6f.jpg

Time to add the rest of the parts.

http://i983.photobucket.com/albums/a...pst2nu3592.jpg

Completely finished.

http://i983.photobucket.com/albums/a...ps4c5j2zw5.jpg
http://i983.photobucket.com/albums/a...psmjsin1la.jpg

Back to case cleaning later in the week. I'm excited about assembling the short block soon!

Great job, man!

Might be worth considering an IMS upgrade WYIT. The stronger aftermarket bearings, or the oil pressure-fed bearing upgrade are popular retrofits to avoid trouble down the road.

Keep up the good work
 

Mihnea,
Good progress, you might beat Santa Claus.

You might consider removing the seal on your new IMS bearing so it gets lubrication although I suspect this new IMS bearing may out last the car. About how much did you have to shave off of the Pelican spacer, oops I guess it was 0.04".....

I am enjoying following your project.

Regards,

Rob

Yep that was it, but the locking ring wasn't engaging properly before and later it did, so I felt much better about the installation.

Thanks!

So we made a bit more progress on the engine today. Namely, we finished cleaning the 4 - 6 case half, installed the 1 - 3 case half back on the engine stand, and dropped the crankshaft carrier into it.

Here are some shots of the 4 -6 case half all cleaned up. Not perfect, but it'll do.

http://i983.photobucket.com/albums/a...psh1cpfjl7.jpg
http://i983.photobucket.com/albums/a...psgwcj9j8i.jpg
http://i983.photobucket.com/albums/a...psiuvzhfdc.jpg

1 - 3 case half back on the stand.

http://i983.photobucket.com/albums/a...pscpiv9p4d.jpg

Crankshaft carrier installed.

http://i983.photobucket.com/albums/a...psuwu7sgkx.jpg

Engine set to U4 in preparation for piston #1 to be installed.

http://i983.photobucket.com/albums/a...ps7zkepcd3.jpg

I nominate this thread for the Hall of Fame! Please keep the pics and progress reports coming.

Good call. Not sure why I didn't do that earlier :roll:

I think that was apparent by the first page or two;) And at only 20-something posts(?) at the time may be the 'youngest' HoF member ever;)

Thanks guys for the HoF induction for the thread. Much appreciated!

Now, for a little more progress. First thing today, we got pistons 1 - 3 ready for installation. The rods were connected to the pistons using the wrist pins and all 6 circlips. Then, we replaced the rod bearings right before inserting them into the cylinders.

http://i983.photobucket.com/albums/a...psyj7byrvj.jpg
http://i983.photobucket.com/albums/a...psepjacteg.jpg

Next, we flipped the case 180 degrees. At the far end, you can see my ghetto replacement for a Porsche tool that is supposed to hold the crankshaft carrier in place while the case is upside down. The near end (by the flywheel) already has two permanent bolts installed, so doesn't need the temporary measure. You can see them both if you look closely. One is in the chain guide housing area and one is outside, just to the SW of cylinder 3 in the photo.

http://i983.photobucket.com/albums/a...psgbpuozrj.jpg

Piston #1 installed. Set crank pulley to position U4 for this.

http://i983.photobucket.com/albums/a...psrip3n2cv.jpg

Piston #2 installed. Set crank pulley to position U5 for this.

http://i983.photobucket.com/albums/a...pskvryhbmm.jpg

Piston #3 installed. Set crank pulley to position U6 for this.

http://i983.photobucket.com/albums/a...ps9pqmwahq.jpg

Next we practiced the installation procedure for the #4 - 6 piston installation. Here we pushed piston #6 into the cylinder and used the alignment tool to set it at the correct hight where the wrist pin can be inserted. Obviously, the connecting rod is currently on the block, so wasn't used for this procedure.

http://i983.photobucket.com/albums/a...psndl1qdnz.jpg

And finally, here is a screenshot from the bore scope of the circlip correctly installed on piston #6. This was just a dry run. Later this week we are planning to bolt the crankcase halves together and carry out the #4 - 6 piston installation.

http://i983.photobucket.com/albums/a...ps645882ee.png