Caterham CSR Trackday toy: Engine upgrade - part #2

Engine out
Bell-housing off
Clutch off
Flywheel off
Mounted engine on stand using bell-housing bolt holes (M10x75 bolts. Use washers to protect the engine.)
Intake plenum off
Removed loom
Fuel rail and injectors (undo nuts and pull)
Coils and plugs
Belt and tensioner

Next up was the first challenge - undo the front pulley nut using hand tools . I used a tremendous breaker bar on the pulley nut, and mounted a spanner as opposite lock on the flywheel, using one of the old flywheel bolts. The spanner was locked against one of the engine stand mounting points. It would have been a lot easier with an impact gun. The pulley bolt shouldn't be reused.

Coolant rail + hoses
Alternator
Starter motor
Oil cooler
Thermostat
Water pump
PCV valve + cover
Cam cover
Front cover

Exhaust cam sprocket.
Cam chain
Chain guides
Oil pump chain tensioner
Oil pump sprocket - tough one. I don't know why it was so tight on my engine.
Cam/pump sprocket on main shaft - thin washer on each side.

Cam chain and oil pumps chain

Now finally I could remove the sump! Be careful with two bushes with five small o-rings that will fall out.

Cosworth dry sump

Note the o-rings

Intake cam sprocket
Cam caps and camshafts. Remember location and direction of cam caps.
Cam buckets. Remember location of each bucket. The size of the bucket is written on the inside, write down for later.

Head off. Torx 55 and breaker bar. But what is that really bad smell!?

Head off

Cotters, retainers, springs and valves. Remember location. Hint: Use a strong magnet to remove the cotters.
I left the valve seats in place. Hopefully they can stay there.

Removing springs

Ordning och Reda

Pistons - will be replaced. Torx 55. Mark them. Direction is already marked as arrows on top of the pistons.

Old pistons

Pistons big end bearings. These will also be replaced, but keep location and direction just in case?

Since I couldn't reach the crank rear seal bolts when the engine was mounted to the engine stand I took it down on the floor and put it on some pieces of wood. Now it was so light I could lift it myself. I also took the opportunity to measure crankshaft play. (0.28mm, spec is 0,22-0.43mm)