finished the job and it started right up!! yee-haw.
several little tidbits that i think might help newbies to these kinds of projects (because i'm something of a newbie... just moving on to this level of work after changing a few alternators, etc...)
- buy a set of misc. size plugs/ caps to seal up the hoses and nipples (hehe) on the radiator as you remove hoses early on
- have lots of drain pans for both transmission fluid and coolant, as both will run out when disconnecting said hose
- on my 96 pathfinder, i found out (too late... after cracking it pulling it out) that the fan shroud has a way to clip out part of the bottom half of the shroud. that would have made removal way easier
- plan on having plenty of room to lay things out, so you can remember what order you removed items. it's an intense job and it gets a little fuzzy on re-attachment
- loosening and removing the power steering pump belt is a pain. the tensioner bolt is tucked away and hard to get to... best access is from the bottom, on the ground. a side-ratcheting box end wrench is ideal for this job. a normal ratchet doesn't really fit and it is very fiddly with a non ratcheting wrench. also, when you've removed that belt, it is an ideal time to go ahead and change your oil filter, since it is right there.
- the cam shaft seals are a PAIN to get out, it'll take some digging...
- i used a steel brush attached to a drill and a dremel with a steel brush to buff the paper gasket residue off from where the water pump was sitting, and to clean the thermostat housing, etc. worked really well and then i used some compressed air to blow out all of the residue.
- rent or borrow and air compressor and air wrench. made this job SO much easier. i don't know how one would remove the cam shaft bolts otherwise... would have been a much harder job without air power.
- once i got it all apart, the previous mechanic had NOT lined up the lines on the belt with the dimples on the cam sprocket. watch out for that kind of thing... the dimples on the sprockets TRUMP the lines on the belt, if the belt has not been installed properly.
- and as others have said, slow and steady wins the race. read and re-read and think carefully about each step.
thanks so much for this write up and for those who've contributed. it is a MIGHTY GOOD feeling to turn that key over and hear that engine start up again after such a big job...
good luck, y'all!!