It’s amazing things you find on someone’s build
 

The following post will take several days to post complete.
Bear with me and enjoy. This photo thesis IS just someone’s build and just one motor.
1976 3.0 Carrera.
New owner changing his oil and pulled the screen to find this steel piece

http://forums.pelicanparts.com/uploa...1667781044.jpg
http://forums.pelicanparts.com/uploa...1667781044.jpg

Still more to get story started
 

Thanks for following the disassembly. It will get better.
Bruce

Nyloc inside the motor, has to be a no no. Must have misplaced the waves washers so he installed nyloc and standard washers.
http://forums.pelicanparts.com/uploa...1667781383.jpg
http://forums.pelicanparts.com/uploa...1667781383.jpg

Half the cylinder dividers are installed backwards. I will post picture of the modified dividers
http://forums.pelicanparts.com/uploa...1667781383.jpg
http://forums.pelicanparts.com/uploa...1667781383.jpg

Modified dividers
 

Novice with a MIG set

http://forums.pelicanparts.com/uploa...1667787113.jpg

I found a cam timing lock pin in the bottom of my crankcase.
What do you think that lump of metal was, or do you think the guy was just wanting somewhere to store it?
Alan

On splitting the case the small intermediate shaft bearing on top half was missing
Fell out from assembly and missed.
On removing the oil screen the owner also found an extra chain rail in the bottom with the steel bearing shell.
Oh, this story is going to get better…..
Bruce

Yikes ! Very lucky it did not self destruct.

My motor had nyloc nuts in the same spot. I won't say who built my motor but he's no amateur. How big a' no no is this?

It can give you some nylon to float in the oil if it were to dislodge.
Bruce

Basically, it's non-factory and it makes you look bad to the next guy who gets into it. Just do it like the factory did, proper washers, nuts, etc.

You think it can’t be done
 

Words can’t do justice to the things in this motor
The ARP rod bolts were stretched out of spec and look at the design that was achieved.
I guess the builder wasn’t paying attention when he took things apart
JE pistons 7.0/1 CR. Owner said compression numbers were around 120# per cyl
These are available for 3.0 turbo build
Bruce


http://forums.pelicanparts.com/uploa...1667859243.jpg
http://forums.pelicanparts.com/uploa...1667859243.jpg
http://forums.pelicanparts.com/uploa...1667859243.jpg

Wow. Just wow.

Those nylock nuts in the first pics aren't locking. There are no threads engaged with the nylon.

If the proper washer was used……but there is still nylon inside the motor
Bruce

Hi Bruce- Glad you got Todd's motor sorted for him; he is a nice guy. :) Michael

Odd things
 

Although it doesn’t make a difference, the through bolts from the factory come through from the other side. I guess the thought was, the nuts from behind the oil cooler so the rest need to come through to the same side….
Bruce

http://forums.pelicanparts.com/uploa...1667922116.jpg

ARP Bolt stretch
 

Hi Bruce. on the over stretching of the bolts...It is difficult to know whether they are overstretched as we frequently see(somewhat alarming) the bolts vary as much as .005" within a set, so unless you have a record of what each bolt length originally was, you'd never know how much they actually were stretched, or whether they yielded- did not return to original length .
Given what else you show in there, I would toss them all and start over.

GL
Kevin
GAS Motorsport

And those damned all thread dilivars in an aluminum case. Ever try sliding a cylinder over a piston with the drag they give? I'd swap for steel and sell those to a mag case guy.

I managed. It was a trip in the past I did load a couple of motors when the 993 studs were about $10 each. The biggest problem with this motor was the removal of the JE 7.0/1 snap rings as there was only one access to the snap ring and it was on the negative side of twist.
Bruce

It looks like some of the connecting rod bolts are installed backwards ! that may be a first .

Bruce,

you don't say.... lol

Took this 2.7 apart on last Friday.... oh my.

http://forums.pelicanparts.com/uploa...1667966307.jpg

http://forums.pelicanparts.com/uploa...1667966353.jpg

http://forums.pelicanparts.com/uploa...1667966371.jpg


But this is not the worst we have seen... 3.2 cylinders installed upside down. Missing fasteners, missing oil pump seals where the "new" engine made ZERO oil pressure. It was a 964 3.6, they removed the oil pressure warning bulb before delivering the car. It made it about 12 miles before it came to us on a flatdeck... And the list goes on.....

I hadn’t seen this before…
 

The oi pressure sender in the lower oil gallery required some work. You have to remove the plug and tap with appropriate threads (or in this case maybe close). plenty of solutions with pressure light and sensor in one to avoid doing this.

john

You mean like in this photo??

http://forums.pelicanparts.com/uploa...1300923901.jpg

Not an uncommon location....and better than the breather cover.

In a perfect engine, no sealant would ever be required. Unfortunately, no engine is ever perfect and we never are prepared to take the risk.

Give someone a tube to squeeze, how do you tell them, don't squeeze too much???

Just think of the cleanup, it’ll peel right off…except in the oil galleys, rocker oilers, the piston squirters, on and on.
Bruce

No, Some early cars did not have a oil pressure sender like the one circled in red. They only had the switch for the light.

http://forums.pelicanparts.com/uploa...1668109172.jpg

You can get early and late (993) senders that have a oil pressure switch for the light and a sender for the gauge all in one. That would have been easier than tapping front for sender.

http://forums.pelicanparts.com/uploa...1668109259.jpg


john

I have a supposed 4.0l built by MotorMeister that will be disassembled early next year. I'll bring you guys on the road to discovery as it comes apart :) I'm an air-cooled newb but I know there are certain ways to do things and I've learned a lot from this bunch - so I'm pretty sure I can spot some craziness in there.

Here is the one I mentioned earlier "rebuilt by pro shop" with cylinders on upside down and 2 piece return tubes.... Motor had about 1000 miles on the "rebuild"....

http://forums.pelicanparts.com/uploa...1668151430.jpg

Cheers

Also VDO/Continental parts providing the warning switch and a 5 or 10 bar pressure sender available in an assortment of thread sizes.

https://www.vdo-instruments.com/sensors/pressure-senders-switches/pressure-sensor-with-warning-contact.html

For example, 360-023 is a combo switch/10 bar sensor in M10x1.0 that O'Reilly list for less than $40. Mine says "Made In Germany" on the packaging.

Just for a neophyte's knowledge, are the two piece collapsible tubes to be avoided? What do you guys recommend when doing a rebuild, the collapsible oil return tubes or the one piece versions? Aluminum or Steel?

Thanks!

The two piece are the only solution to replace leaking ones on a motor that is not coming apart, so they do serve a useful purpose. When rebuilding we only use OE one piece steel ones. Others may have differing opinions mind you.

Cheers

I always enjoy solid return tubes for look and function
Got boxes of split ones used, don’t know why….
Bruce

We've been running a double sending unit for decades. To clean up the wiring we make a custom harness.

http://forums.pelicanparts.com/uploa...1668617537.jpg
http://forums.pelicanparts.com/uploa...1668617537.jpg
http://forums.pelicanparts.com/uploa...1668617601.jpg

Screwing a late sender directly into the case is new to me. I like that option.
Allows for a late double to be fitted.
Moving the sending from the front of the case to the rear cleans up the cam feed lines as well.

Yes, very good idea....can any of you share the part number for the correct double sensor? My engine build is just beginning and I am making a custom engine harness anyway (it is Motec/Rasant for EMS)...so this sounds much cleaner.....

Thanks in advance!

D.

Post #29 in this thread https://forums.pelicanparts.com/911-engine-rebuilding-forum/1129460-s-amazing-things-you-find-someone-s-build.html#post11846671 has a link to the VDO catalog.

I bought 10 bar sensor because that's what my gauge uses/appropriate for 930 oil pump output. I'm fairly confident input impedance on the Motec wouldn't mess with the gauge reading too much if you were to "tee" the original sensor - but for $40, you can add an extra sensor and leave the gauge entirely alone.

Pretty sure M10x1.0 matches the factory pressure switch fitting from what I've read.

Thank you!

D.

Ha! Nice thread Bruce!

More of the messy.. in the process of tearing down 3.2 and find these "unique" RSR rocker seals, aluminum washers on case thru-bolts, and silicone as case sealer everywhere! :eek:

http://forums.pelicanparts.com/uploa...1669051296.jpg

http://forums.pelicanparts.com/uploa...1669051296.jpg

http://forums.pelicanparts.com/uploa...1669051296.jpg

http://forums.pelicanparts.com/uploa...1669051296.jpg

http://forums.pelicanparts.com/uploa...1669051296.jpg

http://forums.pelicanparts.com/uploa...1669051296.jpg

...here in Czech we have some special guy working on 911..and others..it is lovely-NOT to do jobs after him..red silicone everywhere-the time to clean it takes longer then assembly of the engine;-)
The latest is the best ,crushed oil tube on camshaft housing after he put mismatched cyl and piston on engine he rebuild..price( i know that one) $8K...oh well garage is full .time to go to work..oh ya bent valves
btw, thanx again John W.
the mid pic is 993 ..had to do service, nightmare it was
http://forums.pelicanparts.com/uploa...1669153780.jpg
http://forums.pelicanparts.com/uploa...1669153780.jpghttp://forums.pelicanparts.com/uploa...1669154637.jpg

well? i just got in 1973 engine from USA ...(do not know where has been) but some genius put in chain tensioners update kit-lovely...since the chain were too stretched he figured out this--never mind all brown rails...camshaft shims and oil shim upside down..http://forums.pelicanparts.com/uploa...1670925004.jpg
http://forums.pelicanparts.com/uploa...1670925004.jpg
http://forums.pelicanparts.com/uploa...1670925004.jpg