Today at Atelier Kaz - ex-Honda R&D, F1, Indy/CART engineer

Crank Pulley bolt properly cleaned and greased before
tightening it to the spec.








As reported earlier, the cable boot for the oil pressure warning sensor was
cut opened by someone in the past so repaired it with liquid gasket.








Started looking into the heavily corroded CAT stud bolt.

If the flange was not so corroded, I’m happy to heat it up to
assist in pressing the remaining part out but by looking at the state of
the flange and bolt, I was too scared to use excessive heat or shock.

Instead, decided to cut off the remaining part and eventually,
will use the advice that I learnt from another owner to push them out.

Just soaked this one with ATF/acetone liquid for the time being and
deal with the remaining two bolts later.






Some of the bolts and nuts used on this engine were not the OEM one.

I ordered the correct ones but when I tried to install one of them,
I found why it was using the wrong spec with such a long length.

The original thread was completely gone so using the OEM length was not
possible without the use of helicoil. Not sure about the usage on Magnesium
valve cover so decided to cut the longer OEM bolt and used it for the harness
bracket located at the corner of the valve cover.







Based on what I saw inside of this engine and looking at the state of
the TH butterfly, decided to look into the Intake Air Temperature sensor as
carried out in the previous services for other owners.

Really dirty so cleaned it to this level and as I always keep some spare
O-ring for this sensor, replaced it as well.











Thermostat housing was really corroded with lots of oxidation…….
The cover side was also heavily corroded.

It looked as if it was never cleaned before.
Bit concerned about the level of corrosion as it managed to bite into
the area very close to the gasket mating section.
Hope it can create enough seal.


Almost all of the coolant pipes around the engine were more or less
corroded/rusted.








New thermostat installed.










All coolant hoses were replaced and almost all of the cramps replaced as well.








So, the engine is ready to go back into the engine bay apart from
the CAT stud bolts….



Will finish the rest of the coolant hoses on the chassis side while soaking
the remaining CAT stud bolts with the ATF/acetone.


More to follow later.

Kaz