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Join Date: Mar 2005
Location: Saratoga CA
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Smile 3.2 Top End Rebuild Finished - Runs Great

Just finished the top end rebuild and got it installed in the car. Now has 200 miles. Many thanks to Wayne and all on the forum especially Camgrinder. Here are a few pictures one before lifting in and some after.

I am driving it as much as possible waiting to hit 1k miles. Seems to be running very good...no drips and no funny noises. I guess we'll have to wait to find out how I did during the next 50-100k miles.

FYI - fan and housing...bead blasted and clear coated along with some of the AC brackets which turned out not very visible. Most of the tin was satin black powder coated. Some wires covered with 100% teflon spiral wrap. People that came over to help with the lift said it was too clean to use and should be put in a museum.

-Henry

Old 07-13-2005, 11:19 AM
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Very nice!! What mods (if any) did you do?
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Old 07-13-2005, 01:43 PM
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no real mods....but I did send the cams to camgrinder to have them "checked". ;-)
referbed the cylinders and new rings, new stock valve springs, all new steel head studs...pretty boring from the hop up point of view....it is a daily driver..now that my kids need to other cars..it is my only driver unless I get to borrow the wifes Suburban.
Thanks for checking it out and the positive comment.
-h
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1989 3.2 coupe, DIY top end at 77k, now 112k
Old 07-13-2005, 02:38 PM
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Your welcome Henry!
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Old 07-13-2005, 04:05 PM
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Did a CA smog test yesterday on the new rebuild....I was paranoid that it wouldn't pass and then the car would get put on the high polluter list so I got a pretest.
Pretest was very good....readings very low..here are the test for record numbers along with the current maximum permitted amounts for my car or at least a 89 911 3.2.

15mph HC= 6(max. 121), CO=0.01(max.0.76), NO=208(max. 807)
25mph HC=2(max. 96), CO=0.01(max. 0.65), NO=221(max. 746)

Looks like it's running pretty clean at least and O2 sensor is working/etc.

I did this at only 400 miles....I think I could have even done it earlier.

The valves and rings felt like they sealed up very quickly.

-Henry
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Old 07-17-2005, 07:07 AM
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nice work henry, another leak free build!
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Old 07-17-2005, 07:42 AM
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At the risk of bumping when people are no longer interested....

Just did another oil change at 450 miles. If you get the sun on the oil in the change pan you can see the very small sparkles looks like very fine metal flake....I guess this is what Wayne explains. Must be small enough to be getting past the filter. On the drain plugs there is a very fine dark brown "sludge" on the tips. If you put a paper towel against the sludge and wick away the oil what is left is a medium gray colored very very fine powder...I guess this is rings and cylinder material and maybe some cam and rockers. When does this stop happening. So far all still seems to be going well. Keeping my fingers crossed.
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1989 3.2 coupe, DIY top end at 77k, now 112k
Old 07-19-2005, 07:51 AM
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Another technical update...

Oil and filter changed at 700 miles, valves adjusted, updated oil line restrictors swapped in, compression checked, plugs looked at.

Oil - much less very fine "metal flake" in the oil, mag. plugs had some but much less grey very fine powder, oil looking much clearer but this was just 200 miles on this oil.

Valves - a number of the valves were noticably loose, reset all to 0.004 and the idle smoothness was improved.

Compression - checked with engine warm waiting to cool of for valve adjust, range 131 to 136.

Plugs - all looked fairly much the same. I have a picture and can post later if people want

Oil Line Restrictors - oil pressure at idle now definately above 1 bar..used to idle a bit below 1 bar when hot. Seems a bit higher oil pressure for all rpm's but this is hard to measure. Right now I'm only running with 9 qts refill so I can't see very well if the oil level shows sooner.

AX this weekend and car ran very good. Now that I can take the engine to redline the acceleration compared to before the rebuild to say 100 or 110 is much faster.

Cheers,

-Henry
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Old 07-25-2005, 07:32 AM
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Good deal Henry - hope to have similiar results
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Old 07-25-2005, 07:50 AM
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