This is getting to be fun.

Monday Night:  2 Hrs cleaning oil off clutch-side of
the engine
Tuesday Night:  2.5 Hrs cleaning carbon off pistons
and liners
Wednesday Night:  $2 Big-Ass beer night at the El
Rancho
Thursday Night:  Go to bed early because of $2 beer
the night before
Friday (this is where the fun starts)

I spent all day Friday cleaning the engine and engine
parts.  I cleaned the fuel rails and replaced the
injector O-Rings.  I cleaned the throttle body and
painted the intake "manifold".  I spent 2 hours
getting oil off of the flywheel side of the engine
case, and got ready to start putting this all back
together

Saturday:  The new piston rings showed up.  I drove
down to the nearest Sears (60 mi away) and bought a
metric Tap & Die set, piston ring compressor and
piston ring pliers.

Sunday:  Put the pistons back together with new rings,
and installed 3 out of 4 correctly in the block.  I
screwed something up installing the last piston
nearest the water pump.  The wrist pin does not turn
freely on the crank arm - pretty stiff.  I thought
maybe just let it go, and it'd loosen up after about 5
min of running, but I think  I will pull it again
tomorrow morning, and see what I can see.  Better to
pull it with the engine out and disassembled than wait
til I get it back in the van.

Oh - for what it is worth - Boston Bob's gasket &
hardware kit is well worth the $50 over the price of
the Busdepot one.  He includes a few missing gaskets
(fuel injector O rings especially), but more
importantly, he includes all the nuts and bolts, and
studs to put the engine back together.

I got about 3 hours to work on the van tomorrow
morning - that should be enough to pull the #1 piston,
figure out the problem, and hopefully reinstall it.

=====
Mark
84 Rocco
87 Westfalia
96 Rockhopper Comp (commuter)
98 Yeti AS-R XC (freeride)
01 Schwinn Fastback Ltd (in progress)
http://student.fortlewis.edu/~mwmages

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