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rotorhead 03-31-2005 04:02 AM

Rebuild Finished and ready to install
In four or five weeks I have rebuilt my 3.3 turbo engine and tonight it is ready to re-install in the car. I am a relative novice and this was my first rebuild. Thanks to Stephen Kaspar, John Walker, Wayne, 350HP930 and others for the advice along the way.

From this

To this

Guys hold off the cheering until it starts and runs leak free. I am very nervous about the first start.

hcoles 03-31-2005 08:17 PM

I going to be feeling the same way in a couple of weeks. Jim Bauman started his 3.2 the other day and had a cam tensioner issue. The thread is on the forum. I really wish you the best. Are you going to crank the engine with plugs out or plugs in? Wayne doesn't seem to make too big a deal either way. I'll probably opt for plugs out and start without updated oil restrictors to get the best chance of oil to the tensioners. That's my current theory anyway.

350HP930 03-31-2005 08:45 PM

Four to five weeks? I am almost on year two.

Carrera3.5L 03-31-2005 09:26 PM


Originally posted by 350HP930
Four to five weeks? I am almost on year two.
Yeah, no kidding, it took me 10 weeks. It was almost a month just to get all of the machine work back from Ollie's and chase down all of the odds and ends needed for reassembly. Good luck with the install and initial start-up, I'm sure you'll be fine if looks mean anything.:)

Didn't have any issues with my motor start-up and although it's only 3K later it is still dry as a bone and hasn't used a drop of oil.


Jeff Alton 03-31-2005 10:34 PM

Good work, and good luck with intitial start up!


rotorhead 04-01-2005 02:13 AM

Thanks Guys,

I have a busy next few days so it may be up to a week before I get to run it. I am planning on cranking it with the plugs in.

I read Jim Bauman's post the other week with building horror. That is the very sort of thing that worries me. I also caught my 6yr old daughter trying to put washers in the turbo during the rebuild so I ended up locking the workshop whan I was out.

stevepaa 04-01-2005 09:38 AM

I'm like 350. I'm at 6 months and it is my primary car. My wife is getting a little tired of driving me to work. Thank God I can use my daughter's car some weeks.

good luck man.

ficke 04-01-2005 10:31 AM

I am on the fourth month waiting for my case and heads to come back from the machine shop:confused:

350HP930 04-01-2005 04:25 PM

Well, at least my excuse is that I am also doing all of the machine work with the exception of the flame rings and resurfacing the rocker arms.

I am leaving that to the experts who are already set up to do such things.

If all goes well I might actually be done in a couple of months. Then again thats what I told myself over a year ago. :D

I am quite impressed that Steve could get it all done so quickly.

ficke 04-01-2005 04:30 PM

Steve, I am impressed, :) and it looks good. Someday, oh, yes someday I will be there to :rolleyes:

rotorhead 04-02-2005 10:06 PM

Sorry to say there is going to be a delay until I get the engine installed. I inspected the clutch and the rubber center has cracked and fallen apart. I need to wait for a new clutch from our host.

Does anyoneknow what my clutch plate options are?

350HP930 04-03-2005 07:42 AM

Use the spring centered disk from the late 70s 930. It works great.

rotorhead 04-06-2005 07:25 PM


I reinstalled the motor and went to turn it over on the starter and it is frozen solid! Pulled the plugs and still no joy. I said a lot of nasty things.

The engine turned over easily before I mated it with the transmission.. I replaced the bolts that hold the pressure plate to the flywheel with new ones and I am certain that they are hitting the engine case. Funny thing is that they are the same length as the ones I removed... go figure. All I can think is that they are too long and are preventing the flywheel from turning.

More to follow...

350HP930 04-06-2005 08:08 PM

Sorry to hear the bad news. If its not the pp bolts are you sure the throw out bearing fork is properly aligned?

Did the tranny and engine mate up easily?

snowman 04-06-2005 08:46 PM

Did you per chance leave out a spacer on the back of the crank/flywheel? I forget its placement but its about 1/8" thick.

And if it runs leak free, it isn't a Porsche.

rotorhead 04-06-2005 09:00 PM


I didn't remove the flywheel as it was a top end rebuild. Anyhow it will have to wait for a week or so as I have a bit on at work. I'll let you know what I find.

hcoles 04-06-2005 09:29 PM

Juan Penada sometimes appears on this site and has a 930 and had a number of issues with the clutch system and installing the engine and having to take it back out again. If I remember correctly the 930 clutch fork is different somehow and has to held just right during install. If you can't find him drop me a note.

rotorhead 04-07-2005 04:46 AM

I dropped the engine tonight and my suspicions were correct, the bolts I replaced on the clutch pressure plate were 5mm longer than the originals. I should have checked them more carefully before installing them. Makes me wonder about my attention to detail... goes to show you shouldn't rush.

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