Jacob's rebuild thread
 

And so it begins...

Engine is on the ground. Teardown will commence in the next couple weeks.

http://asbury.smugmug.com/photos/621897047_UgJrs-L.jpg
http://asbury.smugmug.com/photos/621897221_zxBEh-L.jpg

Leakdown was 44% on cylinder 6, as I mention in this thread:

http://forums.pelicanparts.com/911-930-turbo-super-charging-forum/487913-leakdown-test-reveals-ugly-truth.html

The engine has about 60k miles on it.

Goals:

To build a reliable street engine, with a little extra performance over stock, upgrades that are complementary to the mods I already have:

K27S, Turbo SSI heat exchanger system by Rarly L8, Rarly L8 muffler, Kokeln intercooler with full 965 intake.

Current plans are:

Take it down to the crank.
3.4 LN Engineering Nickies cylinders and JE pistons (7.5/1 compression ratio)
Heads reconditioned and mild porting (probably to 36mm)
Do the twin plug machine work (to allow for easy future ignition upgrade, just in case)
Might as well do the cams (probably SC)
New headstuds
ARP rod bolts

LN Engineering offers slip fit 100mm P&Cs which will yield a true 3.5 liter. I am considering this route.

Opinions and suggestions welcome

I'll update this thread as I make progress.

cheers!

Special thanks to Pelican Vinny (screen name Vin-barrett), who worked with me today on my virgin engine drop. You are the man! SmileWavy

Congrats! Who is going to do your rebuild?

Yasin

Awesome Jacob - :) glad to see it going in for a bit more pep and a 3.4 will not disappoint! :) hope it goes well :)

I'm doing it with the help of this forum, Wayne's book, and a few wrenching buddies.

very cool
subscribed to the thread :)

If you enlarge the exhaust ports or swap heads that have larger ports you should cone the gasket protectors on the SSI exchangers to match. The ID of the pipes will allow for velocity without choking with the cone transition. This will retain good off-boost torque for driveability as well. I would not swap out turbos until you are finished and see the results. If the desire is low boost street torque monster you may be just fine as is.

I was really only thinking of enlarging the intake side of the heads...is it a waste to do that and not touch the exhaust side? The turbo is practically brand new...I'd rather not change it. I don't plan to run more than .8 Bar.

ohhhhhhh subscribed bro! I didn't think you'd get started on her this early. I thought it was going to be more of a winter project. If you don't plan on turning up the boost, I'd go for the 3.5. no replacement for displacement.

btw, are you going to strip out your A/C or try and recharge it?

Subscribed!!! ,, Make sure you document the$$$ too we'd like to see that

Sub'd... Headed down this road too!

A/C will remain in the car and making it work decently is on the to do list. Engine rebuild is to keep me happy, and the A/C rebuild is to keep my wife happy:).

Where are the pics!

C'mon man ... this is the Turbo board ... we need pics of EVERY step along the way.

Start with the opening of the 1st beer bottle, then the hookers ... oh ... I mean yeah ... engine drop pics.

And DO NOT FORGET the obligatory Jacob in the engine(less) bay pic.

Some progess and some pictures
 

My engine sat on the atv jack for about two weeks after the drop...life got in the way plus there was a little logistical issue that required completion prior to tear down ----> I had to transport the engine from my rented garage (a few miles from my home) to my home garage. The engine move was completed this weekend, and tonight I got to make some progress on the teardown. I removed the engine tin and pulled the manifold and the entire CIS as an assembly.

Engine in the stand prior to tonight's work:

http://asbury.smugmug.com/photos/636281481_X6Uta-L.jpg

CIS injectors "pickled" in seafoam:

http://asbury.smugmug.com/photos/636281573_wg6rr-M.jpg

Manifold and CIS induction removed:

http://asbury.smugmug.com/photos/636281674_ELDiv-L.jpg

I noted that every one of the plastic CIS injector blocks had some amount of cracking. Nothing was visible from the outside, but each had a crack propagating from the inside on the cylinder head side. Cylinder #5 was the worst and there was actually oil underneath the injector block.

http://asbury.smugmug.com/photos/636281780_P6Qcf-L.jpg

remember that I had 44% leakdown on #6, so I was getting a lot of blowby. Crankcase pressure was pushing a lot of oil into the intake. I think that the cracked injector block on #5 was leaking and allowed the oil to seep out. In the past I noted that the threads on #5 spark plug were oily...now I know why.

More to come...

Great work Jake. Taking apart your motor is a fascinating journey into it's inner workings and a truly great learning experience.

Keep the pix coming.

PS - Is that your Duc in the corner? Mandatory pix of her without the cover at some point in this thread.

Jake..

Looks like you're making great progress.. better than me the last few weeks! Good luck and enjoy the journey.

Paul

Keep the pics coming Jake, and I 2nd the mandatory pics of the Duc!

no matter how many rebuild threads I see, I enjoy reading another, subscribed, great stuff!!

Subscribed as well. I would love to tackle something like this someday.