The engine has 117,000 miles and was running really well. I don't think a full rebuild is warranted now so the refurb will just be about replacing clutch plate, sensors, seals, pipes, tubes, gaskets (some of which show signs of oil leak). Also clean the block and associated bits of rust and corrosion and apply some engine paint. Along with all new nuts and bolts etc and we should have a nice clean engine to put back.

First job is to drill out and tap two of the Etorx bolts that sheared off during removal

Clutch and flywheel removed.

Exhaust headers removed. The studs connecting to the main exhaust pipe have sheared, they need dealing with or the whole headers and cat converters replacing.

Oil filter housing and steering pump bracket removed for cleaning and seal replacement.

New Exhaust gaskets needed.

Sump off for cleaning and gasket seal renew. Several of the bolts sheared due to corrosion, they had to be tapped for new bolts to be fitted with new gaskets.    

Vanos refurb

There are a few youtube videos on this. Also the X8R company who supplied the recon kit have good instructions.

The crank and camshafts should not be moved while the vanos unit is away from the engine. So crank is locked with number 1 cylinder at TDC.

Vanos unit stripped and laid out. All bearings, rattle rings, seals, gaskets all renewed.

Vanos unit refitted after a good clean and high temp engine paint job.

Cam cover is now refitted with all new seals.