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The rear wiper blade was gone, and the sprayer nozzle was loose. Both were replaced with new.
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While gluing the rubber seal back onto the wind fairing (with a tube of black E6000), I blasted the debris off the roof.
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This grille was relatively inexpensive from eBay, and easy to install. While it was out, I changed the headlights, too (also from eBay).
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I wasn't sure how hard it would be to find or remove a factory receiver in a junkyard, so I ordered this new one. The next day, I found one in the first JY I went to.
The new headlights are noticeably clearer.
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This folding cargo tray came from WalMart. I also put a set of ratchet straps on it & the roof rack. Later, I had to bend the tailpipe slightly to keep it from rattling against the receiver.
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The cabin filters appear to be factory - even beating them on the concrete, NOTHING came out of them.
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The original speaker suspensions had deteriorated with age, but I had some used ones in my junkpile that fit.
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This dual USB power socket is wired to the cigar lighter. There's also an FM modulator with iPhone fire connector up front.
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I found a replacement armrest on eBay.
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The passenger seat wouldn't slide fully forward, and eventually I found there were several coins trapped in the rail. The only way to get them out was the same way they went in: gravity.
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I cleaned the original negative cable & soldered a new domestic-style terminal on. The cable was barely long enough. I also polished its body & block terminals.
The positive terminal got disassembled, wire-brushed back to shiny metal, greased, and reassembled.
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Changing the reservoir's fluid doesn't change it all, but it's a start. If this is done during each brake service, the old fluid will never be a problem.
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To make turning the crank easier, I changed the timing belt in-chassis. I did the water pump & front main seal at the same time. The seal was a BEAR to drive in...
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With the compressor flipped, the bottom of the high-pressure hose was visible, showing dye. So I ordered this replacement. The refrigerant had already leaked out, so I swapped the hose later during reassembly.
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After pulling the upper intake, several hoses & wires had to be disconnected in preparation for pulling the engine. One of the heater core nipples broke, creating a new problem to be fixed...
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Even after a week not running, there was still wet oil at the top of the bellhousing, running down the separator plate.
The white sealant on the pan gasket is not factory, so this pan was certainly re-sealed before. It appears to have been done in-chassis, which is probably why it has been leaking.
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I used a lifting plate I made for a Ford 5.8L (with 3 new holes drilled) to pull the engine by the lower intake, using the plenum bolts & washers.
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What a nightmare! But it's out...
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The rear main had been driven in too far, so it was easier to pull that housing than try to dig the seal out. While it was off, it was easy to polish the grime off the crank hub and check for a wear groove - there was none.
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It only took 1 of the 2 supplied bags of RTV to seal the oil pan, and I let it dry overnight before dropping the engine back in.
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To access the broken heater core nipple, the evaporator had to come out. Since the refrigerant was already discharged, these lines could be disconnected.
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It was surprisingly easy to yank the evaporator housing out of the dash. Probably ~45 minutes, including reassembly.
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I got a used heater core with nipples from eBay, and just swapped the broken nipple.
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I put some Hylomar on the replacement to help the O-ring make a seal, and put it all back together.
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A few hours later, I backed it out to let it warm up & burn off the oil, and to check for leaks. None were apparent, so I used it the next day to run errands.
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It drove fine at highway speeds, and seemed fixed. But at my first stop, an oil leak became apparent - that front crank seal hadn't gone in right.
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I picked up another front main seal, stripped the front of the engine again, and pulled the orange seal out. I could see a chunk missing from its inner lip. So using a tool I made from a blue plastic rebar cover, the new seal went in MUCH more-easily.
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I washed all the belts (including the timing belt). The 2nd seal dripped a little at first, and then stopped. The last thing to fix will be the A/C...
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The Big Fix