Engine Rebuild Finally Underway

[robwright]

As I have a weeks leave I braved the soggy weather today to finally get the engine rebuild underway. Had a good afternoons work and achieved quite a lot. Everything is going very well with the tear down so far and everything I have removed has been in tip top condition. Got to love this engine. 25 years and 163k up and all is looking good so far. Biggest surprise of the afternoon was how easily the exhaust manifold bolts came off. Just a few pics of progress if anyone is interested.

Right let's get started.

Inlet manifold off.

Ready for the cam tower to come off.

A finally it's off.

 

[POR1983]

Great photos keep it up, threads like this are a good reference for various jobs.

 

[Mike_Pollock]

And there was me telling my wife that its too wet outside[]

Looking good so far, hope the rest of it goes as well.

 

[zcacogp]

Rob,

Glad to hear that weather didn't hinder the work on your Ferrari.

Remind us what the problems are that you are seeking to resolve?

Keep it going with the photos. They are helpful for all 944 owners - turbo owners more than most, but it's all good stuff.


Oli.

 

[robwright]

Oli I had started to be come concerned about the oil usage and the puff of blue smoke under hard acceleration whilst overtaking S2s. A compression test revealed low readings on all four cylinders that improved somewhat with oil down the barrels. This would indicate worn rings and at 163k I wasn't surprised frankly. Due to the amount of work involved in doing the rings I decided to do a mini rebuild. So I will be re-ringing obviously plus new big end bearing shells and a widefire head gasket. The head gasket and sump kits that ProMax sell just about cover all of the seals in the engine so hopefully by the time I have finished she will be good for another 163k. I will also be wrapping the exhaust downpipes and crossover to the turbo. To both improve performance for now and if I wish to add any more S2 thrashing mods in the future []

 

[Hairyarse]

Good progress Rob. Sorry mate but can't get oily with you this week. My week off has switched to a week in Estonia with work - Not happy [] Dan was looking forward to a petrol-head week too

Good luck, catch you next weekend

PS: I'll still eat the Lasagne for you if needed []

 

[zcacogp]

Rob,

Context is helpful, thanks. All the best with the rest of the work. Any idea how long it will take you?

I shall await a sound thrashing. (I suspect I may be waiting some time. Make of that what you will! [])


Oli.

 

[robwright]

Jesus Christ Andy do you ever sleep mate? Bummer about the week off. All I can say is you must be due one hell of a bonus this year [] Get your ass over at the weekend anyway. I have just put lasagne on the menu []

 

[Hairyarse]

I know tell me about it! Seriously need a week off. Need to get the belts sorted on mine soon too, hopefully may help it sell

 

[robwright]

ORIGINAL: zcacogp

Rob,

Context is helpful, thanks. All the best with the rest of the work. Any idea how long it will take you?

I shall await a sound thrashing. (I suspect I may be waiting some time. Make of that what you will! [])


Oli.

Oli the world would be a dull place without you in it fella. I reckon 2 or 3 afternoons this week and may be another 2 or 3 weekends working Saturdays as I see my kids on Sunday. Not in any rush as I have the car SORN at the minute. Want to make sure everything is tip top. Silly not to with this level of work.

 

[robwright]

ORIGINAL: Hairyarse

I know tell me about it! Seriously need a week off. Need to get the belts sorted on mine soon too, hopefully may help it sell

Does that mean I have to help you do the belts on your current car just so that you can sell it then I have to help you do the belts on your new car??? []

 

[sulzeruk]

Give it a good flush Rob, it looks pretty black in there, you been using some of that LZF 66 oil from work. Never seen one as black in that in a while.
Al

 

[George Elliott]

Rob
good work, but tape up those inlets - accidents waiting to happen. Same applies if you have the I/C, or inlet components off.
keep us posted
good luck
George
944t

 

[robwright]

Thanks Al yeah I am not sure if that is the 20w50 oil I have been using actually. Everything that comes off will go back on spanking and it will get a flush. My first time stripping one of these so might give you a call if I get into any trouble mate. Talking of which what is the usual running in procedure for these engines after new rings? I was thinking 300-500 miles of conservative driving then an oil and filter change??? George all of the IC and turbo tubes are plugged with rags. I would normally and have in the past taped over the inlet ports as well but the whole lot is coming off and the cylinder head is getting stripped down and valves lapped etc.

 

[Hairyarse]

ORIGINAL: robwright

ORIGINAL: Hairyarse

I know tell me about it! Seriously need a week off. Need to get the belts sorted on mine soon too, hopefully may help it sell

Does that mean I have to help you do the belts on your current car just so that you can sell it then I have to help you do the belts on your new car???  []

Er no, I'll try and buy one with belts done []

Just need to get my covers off next weekend to see if got new or old type water pump then order belts so shouldn't be an issue. Can then give you a hand

 

[robwright]

Give us a shout as soon as you are ready mate. First time doing a set of belts on one of these it can seem a bit daunting. I even thought about paying to get it done the first time but it's not that bad really when you get into it. Seriously though lasagne time this weekend. If you are bringing Dan I will order in an extra few hundred weight of beef mince []

 

[barks944]

Some tips from somone who's just done it:

Check the alignment of the bearing cage very carfully, I found mine had warped or grown somehow and was creating misalignment around the bearings and the front of the block even when sat on its locating pin. We very carefully made an offset pin to bring it all exactly back into line.

Make sure you use the right sealant on the balance shaft housings and the oil pump. I used the red loctite that supercedes the one Porsche recommend and its been great (I'll get the number if you want it). The oil pump especially needs a very good seal or it will leak a ton of oil, especially if there is misalignment on the sealing face between the oil pump and block. Although the loctite will seal up a reasonably sized gap.

Take your time to find lots of the nuts and bolts from a supplier other than Porsche! I will be pleased to offer advice if I can.

 

[robwright]

OK more work done on the engine today.

Exhaust headers off.

Cylinder head finally gives in lol.

The worst head gasket in the world by far!!!

The trouble is I am now in two minds as to wether this engine needs rings or not. The HG is pretty disgusting and has obviously never been changed. It would certainly explain the cross contamination of the oil and there was evidence of boiling water on the crowns of 2 and 3 piston. I know the valve stem oil seals need doing explaining some more of the oil consumption. However would it explain the low compression on all cylinders that improved when oil was added? Also would it explain the low AFRs I have been seeing? These are the bits I am unsure about. Doing the rings and big end shells is a considerable increase in cost. However do I want to risk not doing it just to have to go through this whole process again? If anyone would like to share any experience or advice then it would be welcomed. Thanks guys

 

[barks944]

What is the wear lip on the bores like? I guess if you poured oil into the cylinders all it could really do is seal the rings better so you probably have some ring/bore/piston wear. How many miles is it on? What were the compression figures? Remember its a low compression engine anyway! My inclination would be that unless your going to do a FULL rebuild or the compression figures are awful you should just sort the cylinder head out and put it back together as is.

 

[sulzeruk]

If oil down the bores helped raise the figuares by a fair bit, the rings need changed. The oil looks very black as well Rob so could be gummed rings as well. What oil have you been using in it? Don't use your stuff from work or you will bugger it as the bearings need zinc/ZDDP for lubrication. 20W/50 is too thick as well really for a turbo engine I think if that is what you are using. I also noticed your 2 centre inlet ports are oily or carbony as well, leaking valves or heavy crankcase breathing. Check your breather pipes are not blocked out of the oiler filler pot and make sure there are no splits in the right angle hose that comes out the top as these are very prone to coming loose or splitting. Give me a bell if oyu want a chat about it, you have my number.
Al