Well gents, took a bit more time than anticipated since it was my first engine replacement ever (except for 50 cc bikes). Nevertheless, she's purring like an (aroused
) kitten again. As promised, some pics:
First removed the top end to assess the damage (before deciding what to do):
As you can see something went terribly wrong here. Before you say 'timing must've snapped' - the belt was on perfectly and on perfect tension as well. Also, note that the second valve from that cylinder/bank is not dent or bent. The valve stem just broke
The result was a nice hole in my piston, which meant that a top end overhaul was not a viable option:
Would have needed to flush the engine, replace the heat sink since it might have cought debry, etc etc.
So ended up with with this nice 163k km engine for 400 euro (bout 350 quid). It's a CF2 petrol engine. Mine runs on LPG but only the intake manifold is changed for that so quick replacement.
Took about 2 hours to drop the old engine (already had top-end disassembled to asses the damage). Took off exhaust, wheels & drive-shafts, airco compressor, power steering lines, and all the little connections that you only discover when wondering why she's not dropping any further.
Then took about 2 hours so change over all the accessoiries (power steering pump, alternator, multi-belt tensioner, water pump (just done my old one 20k kms ago), inlet manifold (due to LPG injection mod), crankshaft position sensor ('new' one looked doubtful), ECU and throttle body, and replace the timing belt.
Then took another 2 hours to discover that even more had to be changed over since it wouldn't fit. One was the cooling water pipe thing that runs under the exhaust was slightly different and didn't fit with CF3 exhaust manifold. The other was the petrol injection rail. Double-checked the fuelline plug and rail, couldn't find any difference, but there must have been a slight one since the 'new' rail and old line ended up flooding the garage with petrol. Only noticed after about 5 seconds of turning over, luckily there weren't any sparks while turning over!
Also had some issues with the mounting blocks, which were completely rusted up, and then discoved I still had to reconnect the power steering lines after having just completed the engine replacement. No way to get at it, so took a lot of fiddling and a Chinese bloke with very small hand and rubber bones, but eventually made it.
All that's left to do now is hope and pray my 'new' engine will last a bit longer. I'm off for a spin, cheers for your suggestions!