Thanks for the help and suggestions - I really appreciate it. This will be my first rebuild, so I'm sure I'll be looking for additional pointers along the way.
On Saturday morning, I hadn't made the decision to strip the thing, and was hoping I could get by with a good descaling. I ran some descaler through and let it heat up in the boiler. I then used the tip on removing the water level sensor connection to force the boiler to overfill, and I opened the steam wands until the started shooting water. I turned the machine off, unplugged, and returned 5 hours later and flushed.
However, I still had a couple issues that would require at least some surgery, I spent some time running the machine to get an idea of where the problems areas are before I began the tear-down. There was an intermittent leak somewhere around the autofill solenoid. It's kind of tucked into the corner of the frame, and I could only see one side of it. One of the opv's on one group is always open, so when the pump comes on, the opv tube is always draining. There was one other slow leak on the supply line to the pump. The electronics all worked on one group, but on the other the auto dosing buttons didn't work (but the manual button did). Maybe they just need programmed - we'll see. At this point, I realized that I would need to remove a number of pieces just to get to the problem areas. That, and Mark's encouragement to tear it down made me decide to strip it. Let the tear-down begin.
Armed with camera and wrenches, I went to it. As I removed each piece, I took a picture of the piece in the proper orientation. Hopefully, reassembly will not be too much of a guessing game. I did find that some of copper tubing nipples were extremely hard to remove from its fitting, and I had to resort to a sharp smack at the juncture of the two. I got pretty good at this.

I did have a steam wand casualty - it just broke off at the swivel. No problem, it looked like a mismatched wand anyway.
By this evening, I had all the tubing out, some electronics removed, groups removed, and boiler removed.
Question: Is there any pieces that should not be soaked in descaler (citric acid)? I've got brass groups and other parts descaling in one bucket, the copper tubing soaking in another tray, and the boiler in a bucket. Is there any pieces that I shouldn't be there? I'm glad I decided to do the tear down. Check out the boiler pictures. UGGGG! I do think that the initial descaling was helpful, because the scale was just coming off in sheets. I was able to scoop out most of it before putting the boiler into fresh solution.
More to come,
Ross

