Hi everyone,
My good friend handed down his manual MCS to me which has about 190k miles.
The car was reasonably well maintained, but given the mileage, it needs a bit of a rebuild.

The main issues are:

• Steering: The steering wheel has about ½" of play in each direction and there's a clunking noise.
• Gearbox: There's a loud rattle when the clutch isn’t pressed in neutral.
• Clutch: It's starting to slip.

The subframe bushings are probably shot as well, so I plan to replace those (front only for now), along with the timing chain. Given the scope of work, I’m considering pulling the engine.
Now, I've already done some research and listed the parts I’m planning to replace below but was wondering if there is anything else I should do while the engine is out?

I'm reasonably well equipped with standard tools, which have worked fine for maintaining most of my cars. That said, are there any special tools I should plan for that would make the job noticeably easier?
I'm also still on the hunt for an engine hoist, but in case I can’t get one, is there a less sophisticated way to pull the engine without a hoist?

Parts list so far:

Supercharger parts:
Part: O-Ring / Part Number:11437513891
Part: O-Ring / Part Number:11517509186
Part: Oil / Part Number: 12345982 Note: Which brand is recommended?
Part: Outlet Gasket / Part Number: 17511520044
Part: Inlet Gasket / Part Number: 11610020836
Part: Water pump / Part Number: 11517520123 Note: Which brand is recommended?
Part: Connection Flange / Part Number:11517509170
Part: Belt K060532 or K060535
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Clutch Parts:
Part: Clutch Kit (LUK)
Part: DMS (LUK)
Part: Mounting Screws (6x) / Part Number: 21207520449
Part: Slave Cylinder / Part Number: 21516777428 Note: FTE good?
Part: Clutch master / Part Number: 21526774078
Part: Guide Tube / Part Number: 23117551719

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Timing Chain:
Part: Timing Chain with guides (INA)
Part: Profile Gasket / Part Number: 11141485162
Part: Upper Seal / Part Number: 11411485173
Part: Lower Seal / Part Number: 11411485172
Part: Front Seal / Part Number: 11111485171
Part: Hex Bolt with seal / Part Number: 07131485184

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Steering:
Part: Lower Steering Column / Part Number: 32306870777
Note: Should I use Mini OEM or Dorman or Lares?

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Bushings:
Part: PSB Front Upper Control Arms (Rear)
Part: PSB Front Sway bar bushings
Part: PSB Rear Sway bar bushings
Part: Steering Rack mount
Part: Vibra-Technics engine and transmission mounts

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Random Parts:
Part: Oil pan gasket / Part Number: 11131487221
Part: Fuel Filter
Part: Oil filter
Part: Cabin Filter
Part: Engine oil
Part: Transmission oil
Part: New O2 (NTK)
Part: Manual transmission (BKE with aftermarket diff)

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Performance Parts:
Part: ST XTA suspension upgrade
Part: GRS intercooler
Part: 17% pulley
Part: 550cc injectors
Part: Aftermarket LSD
Part: Scorpion catless manifold
Part: Adjustable rear control arms

Thanks,
Tom

 

Things to do with the engine out? I strongly recommend replacing ALL of the hoses in the cooling system and replacing the plastic tees and thermostat housing with metal ones. I had a bad experience with a plastic tee in the cooling system breaking on me while driving (documented here) resulting in my replacing the engine. I don't know if you have a power steering fluid leak, but with the engine out and you are doing steering rack bushings and swaybar bushings, it would be super easy to replace the power steering lines and reservoir.

You may also want to replace the stock crank pulley (AKA "harmonic balancer") with an ATI super damper. The stock pulley is known to break and shred the belt at the worst time. ATI super damper won't break.

If you have a lift, you could drop your engine/transmission on a table and lift the car off of it, otherwise, I would spring for a hoist. And an engine stand.