91 Turbo 3.4 rebuild begins

[Henry Schmidt]

SUPERTEC has started the assembly of a 91 Turbo for Infrared Camera.
We will try to document this process for all of you who care.
Case is prepped and ready to go.
Note the slight machining necessary for the GT3R oil pump. Cool or what.


Note the secondary scavenge pump. This pump has 3 stages.

The bearings have dry film moly lubricant.

And of course we use SUPERTEC head studs.

[iamchappy]

I see ya picked up one of those GT3R pumps, how much work to make it fit in my 3.0 case.
Henry I plan on stopping by the shop when Im in town next week if thats ok with you.

[Henry Schmidt]

Rods were rebuilt and balanced to 0 grams +- .1 gram.

ARP rod bolts and nuts were used.

Rotating pieces were balanced to 0 grams +- .1 grams as an assembly and individually.

[axl911]

Anything special you do to prevent leaks when installing the thru bolt o-rings or cylinder base gasket?

I followed the book very carefully, but still end up with leaks on the thru bolts and cylinder base gaskets.

Or are these things just a pro builder's experience.

thanks,
anthony

[Henry Schmidt]

We use only green case through bolt orings and lubricate them with silicone oring lube.
Dow Corning 55 O-ring lubricant. (Mil. surplus)
This product is used on all o-rings we install in 911 engines.

BTW: Is your engine an early 3.6 Carrera II. Some of the 3.6 cases had a recall that advised to use two o-rings on each washer(4/bolt). Apparently Porsche had manufactured some of these case incorrectly.
You should have heard the heat I took from another engine builder for using two o-rings. He convinced the engine owner we had no idea what we were doing until we showed him in writing. That shop shall remain anonymous, but it would surprise you.
This same race shop tried to tell me we sent them the wrong headers until I saw the picture of them trying to put the headers on backwards.

[jpnovak]

Did the anonymous shop tell you the grease was out of date too? LOL.

[porschett]

Henry,

Please keep the pics comming. I'm in the process of putting my 3.3 back together and these pics are an inspiration.

I'm only doing the top end, but decided to replace the rod bolts and nuts with ARP. Can I replace them w/o splitting the case? Or should I go ahead and split it anyway?



Thanks.

[Henry Schmidt]

Originally posted by jpnovak
Did the anonymous shop tell you the grease was out of date too? LOL.

It's out of date but it still tastes good.

Originally posted by porschett
I'm only doing the top end, but decided to replace the rod bolts and nuts with ARP. Can I replace them w/o splitting the case? Or should I go ahead and split it anyway?

I have never liked mounting a rod to a crank without being able to rotate to rod around the journal. I like to feel the rod in every possible position.
It is also my practice to rebuild a rod when ever I separate it. When a rod runs in a engine it takes a set with the bolts and bearing it is assembled with. When I change one I change them all.
My thought : split the case. you're only 6 hours away and bearings are cheap insurance.

[Henry Schmidt]

A few more steps.
New Mahle 98 MM pistons and cylinders.
Note the Supertec Head studs.

The green band holding the rod is an old 3.6 cylinder base seal.
Anti seize on heads stud threads.
38 mm intake port for good top end and improved anti reversion action at lower rpms.

[porschett]

Wow, it's better than from factory! More, more please.

I notice you put the cylinders after the pistons are on the rods. Good tip for me.

[89turbocabmike]

Keep them coming Henry, you've got me drooling all over the keyboard At what point is the GT3r pump needed(multiple oil coolers?), or can you never have enough? What cam is planned?

[JasonAndreas]

Originally posted by Henry Schmidt
BTW: Is your engine an early 3.6 Carrera II. Some of the 3.6 cases had a recall that advised to use two o-rings on each washer(4/bolt). Apparently Porsche had manufactured some of these case incorrectly.

For future reference (and for axl911) the TSB is number 9107 and says, "

Some crankcases were assembled in production with two sealing rings and modified sealing washers under the nuts of the crankcase mounting bolts (Figure 1).

Engine number ranges:
62L11289 through 62L11307 manual transmission
62L12581 through 62L12801 manual transmission
62L51104 through 62L51140 Tiptronic"

When assembling crankcases within the above engine number ranges, the two new sealing rings along with the modified washers must be reinstalled under the nuts of the crankcase mounting bolts.

The modified washers are shortened to 5.8 mm (new washers-6.3 mm). If a washer is lost or damaged, a new washer Part Number 964 101 313 02 must be reworked to dimension 3.3-0.1 mm as shown in Figure 2."

[JeremyD]

Nice Henry - how'd you get the case so clean? What cams?

[Henry Schmidt]

Dishwasher and patience.

964 cams from John @ Dougherty Racing Cams.

http://forums.pelicanparts.com/drcamshafts.com

[JeremyD]

Ah yes, have the DRC cams myself. What's your take on flameringing? I take it this engine won't see too much boost?

[Henry Schmidt]

I am on the fence with flame rings. The flame ring is designed to keep the combustion chamber sealed under boost when the heads lift off. With steel studs or Delivar studs and even Raceware studs the heads lift off even on normally aspirated high performance engines.
With SUPERTEC head studs, the heads do not lift even with 1.4 bar of boost. (800+ hp).

Are flame rings a good idea? Yes but Supertec head studs may make that mod obsolete.

[Henry Schmidt]

Sorry about the lack of continuous pictures.
My camera broke and we couldn't stop building the engine while I waited for a new one.
We did make one change in the build sheet. We are now using a K27S turbo charger from Image Auto. www.imagineauto.com/ Great guys and good prices.

[Tom F2]

Very nice! What is the pump mounted forward on the right bank? And what is the gold bracket behind it?

[Henry Schmidt]

Power steering pump and air conditioning pump bracket.


I know. What the h*ll are those things doing on a Porsche?

If I had my way.............

[porschett]

Nice Henry,

Where can I find the rubber wire looms you used?