Helpful ReplyTurbo Engine Rebuild

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PSH PCGB Member Total Posts : 3519 Joined: 2023/07/07 12:40:43 Status: offline PSH PCGB Member Re: Turbo Engine Rebuild 2022/04/06 16:00:16 (permalink) blade7 You don't want high load at low revs. And you should increase the boost gradually over the the first 1000 miles. Every factory engine has probably been run to highish revs from new. Manufacturers wouldn't do that if broke engines. I'll have to disagree on that one Paul... the rings need load to bed in, perhaps using the word 'heavy' was misleading but it needs to be substantial. Foot to the floor and back off again for short bursts only, no motorway driving, no driving at constant speed until the rings are bed in 944 Turbo......was 368BHP/382Torque.... now more... Quote Reply #101
Eldavo PCGB Member Total Posts : 3845 Joined: 2010/08/26 13:22:41 Location: Newcastle upon Tyne - I am not a Geordie though! Status: offline Eldavo PCGB Member Re: Turbo Engine Rebuild 2022/04/06 21:23:50 (permalink) My mate Alex* suggested the following break-in procedure: 4th gear 30mph - floor it until you hit 70 and then let it coast back down. Repeat x10 and that’s the rings bedded in, change the oil and filter. Then do 150-200 miles at a mix of loads and revs, still at low(ish) boost, change the oil and filter. Go drive! *He builds engines for the Aston Workshop that are worth more than any of our cars. Joint 944 Register Secretary, 944 Forum Moderator Current: 1988 944 Turbo S (now 3.0 16v turbo 400bhp+) 2022 Tesla Model 3 Long Range 1966 Triumph Tiger 90 Past: 2002 996 3.6 C2 2006 987 Boxster 2.7 1988 944 2.7 Quote Reply #102
PSH PCGB Member Total Posts : 3519 Joined: 2023/07/07 12:40:43 Status: offline PSH PCGB Member Re: Turbo Engine Rebuild 2022/04/06 21:53:43 (permalink) That's it.....:) 944 Turbo......was 368BHP/382Torque.... now more... Quote Reply #103
blade7 Guest of the Club Total Posts : 2676 Joined: 2008/06/06 12:28:26 Status: offline blade7 Guest of the Club Re: Turbo Engine Rebuild 2022/04/06 23:18:55 (permalink) My race engine builder mate said, run it in hard and it makes more power. Also said it doesn't last as long though. Didn't worry him, he got paid to refresh the engines. I've run in 3 brand new engines that revved to 14k.... Quote Reply #104
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/16 09:27:11 (permalink) ☄ Helpfulby Eldavo 2022/05/17 00:12:02 Well after going this far I have decided to try and cure a slightly noisy lifter issue whilst the engine is out. Simon over on TIPEC kindly sent me 9 good used lifters and from them and the 8 I already had we will pick the best 8 and get them stripped and cleaned. Cost new is an eyewatering £58 each and there seems little availability regardless. Compare this to the readily available new cost of less than £6 for compatible 16v lifters and it makes you shed even more tears!! My mechanic friend has finally told me he will be starting on the rebuild and re-fit process this week (albeit not dedicated full time to it) so with a bit of luck we should now only be 2 or 3 weeks away from hearing some purring! Been a long time and can't wait! Cheers Stuart '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #105
blade7 Guest of the Club Total Posts : 2676 Joined: 2008/06/06 12:28:26 Status: offline blade7 Guest of the Club Re: Turbo Engine Rebuild 2022/05/16 19:16:55 (permalink) How are you going to run it in though... Quote Reply #106
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/16 20:31:15 (permalink) blade7 How are you going to run it in though... Slowly......... '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #107
blade7 Guest of the Club Total Posts : 2676 Joined: 2008/06/06 12:28:26 Status: offline blade7 Guest of the Club Re: Turbo Engine Rebuild 2022/05/16 22:49:15 (permalink) Good plan. Quote Reply #108
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/25 18:10:42 (permalink) Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons! Built up the balance shafts today with new bearings and bushes, alternator back on and some other bits and pieces. Play was stopped when the new waterpump was incorrect, it was blanked off for the coolant elbow. New one should arrive tomorrow and we can get the front end built up. Also note my shiny new heat shield that was discussed on the other thread awaiting to be fitted! Also note the new fabricated head stud my engineers made up to replace a broken one. The thread in the block also needed repaired and they have made up a stepped stud which will be stronger than ever. All going to plan should be ready early next week to put back into car. I'm getting excited!! Stuart post edited by scam75 - 2022/05/25 18:25:49 '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #109
Eldavo PCGB Member Total Posts : 3845 Joined: 2010/08/26 13:22:41 Location: Newcastle upon Tyne - I am not a Geordie though! Status: offline Eldavo PCGB Member Re: Turbo Engine Rebuild 2022/05/25 22:37:54 (permalink) Would now be a really bad time to tell you that that’s how the waterpumps usually come and you drill out the hole as the material is thinner and/or demarcated in that area Joint 944 Register Secretary, 944 Forum Moderator Current: 1988 944 Turbo S (now 3.0 16v turbo 400bhp+) 2022 Tesla Model 3 Long Range 1966 Triumph Tiger 90 Past: 2002 996 3.6 C2 2006 987 Boxster 2.7 1988 944 2.7 Quote Reply #110
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/26 09:24:07 (permalink) Eldavo Would now be a really bad time to tell you that that’s how the waterpumps usually come and you drill out the hole as the material is thinner and/or demarcated in that area Probably, lol! I will call my mechanic!! However with hindsight, there are no threaded holes to secure the plastic elbow on this one either, just a flush piece of metal, surely you can't be expected to drill and tap the threads as well???? Lol, lol, lol I think we'll wait and see what ECP deliver today before reaching for the power tools!! Cheers Stuart post edited by scam75 - 2022/05/26 09:28:56 '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #111
blade7 Guest of the Club Total Posts : 2676 Joined: 2008/06/06 12:28:26 Status: offline blade7 Guest of the Club Re: Turbo Engine Rebuild 2022/05/26 18:44:28 (permalink) scam75 Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons! All going to plan should be ready early next week to put back into car. I'm getting excited!! Stuart Looks good. Do you know what the piston/bore clearance is. And has anyone mentioned some piston slap from cold? Quote Reply #112
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/26 19:19:53 (permalink) blade7 scam75 Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons! All going to plan should be ready early next week to put back into car. I'm getting excited!! Stuart Looks good. Do you know what the piston/bore clearance is. And has anyone mentioned some piston slap from cold? Thanks, it does! Yeah we are standard size piston/bore clearance, 100mm pistons and 100.5mm bore clearance. Con rods have been slightly offset to minimise slap from cold. Stuart '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #113
blade7 Guest of the Club Total Posts : 2676 Joined: 2008/06/06 12:28:26 Status: offline blade7 Guest of the Club Re: Turbo Engine Rebuild 2022/05/26 19:41:26 (permalink) scam75 blade7 scam75 Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons! All going to plan should be ready early next week to put back into car. I'm getting excited!! Stuart Looks good. Do you know what the piston/bore clearance is. And has anyone mentioned some piston slap from cold? Thanks, it does! Yeah we are standard size piston/bore clearance, 100mm pistons and 100.5mm bore clearance. Con rods have been slightly offset to minimise slap from cold. Stuart I remember back in my Cosworth days, that supposedly the Sapphire Cos had the gudgeon pins moved in the pistons to stop the idle rattle. Though JE's do still have a reputation for knocking from cold. Quote Reply #114
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/26 19:45:16 (permalink) I'm sure there will still be some knocking from cold but the guys have took steps to minimise it, so can't do any more!! '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #115
blade7 Guest of the Club Total Posts : 2676 Joined: 2008/06/06 12:28:26 Status: offline blade7 Guest of the Club Re: Turbo Engine Rebuild 2022/05/26 23:44:01 (permalink) Despite what is often stated on the internet, it seems a bit of a mystery what the original Porsche pistons are made from. The original clearances are very tight, which seems to be why there's little noise from cold. But forged pistons usually expand more than cast, so require more cold clearance. Make of that what you will... Quote Reply #116
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/05/30 18:03:06 (permalink) ☄ Helpfulby Eldavo 2022/05/30 21:37:24 Engine ready to go back into car now, when, I'm not so sure, hopefully soon! Oil cooler assembly back on, new heat shield on, turbo back on, new water pump on (much better with cutout and holes for coolant elbow ), back belt cover on, various other heat shields and brackets on. Getting there! Stuart '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #117
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/06/06 10:39:44 (permalink) ☄ Helpfulby Eldavo 2022/06/06 11:06:18 Just spoke to my mechanic. The engine is going back in tomorrow evening. Then we can get the head on and start bolting everything up. Home straight now!! Stuart '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #118
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/06/16 09:25:08 (permalink) Well some more progress yesterday, no pictures though! Engine is back in car, head is on and torqued up. Next up is to fit the clutch and then get it timed up. My mate is snowed under today but hopefully he will get back on it on Friday. It obviously up on his ramp now (1 of 2 ramps) so we should be looking at days rather than weeks now to completion! Seems like ages but literally on the home straight now. Lots of fiddly little jobs as you can imagine, broken connectors on loom etc. to be attended to so slow and steady wins the day! Stuart '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #119
scam75 Guest of the Club Total Posts : 2145 Joined: 2009/08/09 10:35:30 Status: offline scam75 Guest of the Club Re: Turbo Engine Rebuild 2022/06/20 21:19:44 (permalink) ☄ Helpfulby Eldavo 2022/06/20 23:36:29 Clutch is built up and reference sensors gapped when I dropped in the expansion tank and hose today. He had a job cancelled today so was getting on my car most of the day! He thinks it will be running this week then he's away for a long weekend. I'm assuming he plans to do some testing and running in as he says I'm not getting it back this week as he tidying up a lot of wiring and plumbing in and around the inlet manifold, which he plans to take his time making it all perfect. I won't complain. Still needs MOT'd as well. We get closer............ Stuart '90 944 Turbo - Sunroof delete, Factory bridge spoiler, CS wheels, CS steering wheel, 1st MY90 turbo in UK Promax L2 chips, SciVision MAF, Lindsey DPW, MBC, Forge recirc valve, 3 bar FPR, K&N panel, GAZ Gold, wideband AFR, Sytec Motorsport Fuel Pump. Quote Reply #120

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Helpful ReplyTurbo Engine Rebuild

You don't want high load at low revs. And you should increase the boost gradually over the the first 1000 miles. Every factory engine has probably been run to highish revs from new. Manufacturers wouldn't do that if broke engines.