My 3.2 engine rebuild
 

Started my engine rebuild last October (05) and I have taken a series of photos which are herehttp://www.impactbumpers.com/forum/index.php?showtopic=430

I am very anxious to take a look, but the website gives an error....

The link should work, but here it is again:
http://www.impactbumpers.com/forum/index.php?showtopic=430

Peter,
Was curious, too. Unless you have a log-in, you cannot see the photos. Maybe post them here, too?

Doug

Pulled the motor & box last October.
Motor was blowing oil, box clashing on second - so descision was made.
Since then, I have done a complete top-end rebuild.
Heads were fully reworked at cylinder head shop http://www.cylinderheadshop.co.uk/
New valve guides, with really tight tolerances -better than Porsche.
New rings fitted on pistons.
Retaining standard cam.
Parts from Pelican.
The motor is now all-but finished - ready to put inlet maniflod and stuff back on.
Then the gearbox goes on the stand!
Some photo's attached.
Can post more later. At least this site has some good storeage capacity!
Well done on starting this site.

This was the easy bit.

Heads - exhaust ports, complete with tired studs -see later photos

Typical barrel - see the hone marks.

Cylinder head sensor - a real pain to remove?

Some photos of various parts back from the machine shop.
Cleaned with glass bead.
Seats & valves re-cut.
New guides.

http://i79.photobucket.com/albums/j1...s/PORTCL14.jpg

http://i79.photobucket.com/albums/j1...s/PORTCL13.jpg

http://i79.photobucket.com/albums/j1.../VALVECL12.jpg

http://i79.photobucket.com/albums/j1.../VALVECL11.jpg

http://i79.photobucket.com/albums/j1.../VALVECL10.jpg

http://i79.photobucket.com/albums/j1...s/VALVECL9.jpg

http://i79.photobucket.com/albums/j1...ts/HEADCL8.jpg

http://i79.photobucket.com/albums/j1...ts/HEADCL7.jpg

http://i79.photobucket.com/albums/j1...ts/HEADCL6.jpg

http://i79.photobucket.com/albums/j1...ts/HEADCL5.jpg

http://i79.photobucket.com/albums/j1...DREPAIRCL1.jpg

With all the parts ready, its time to begin re-assemble.
New Goetze (OEM) piston rings were fitted. Piston ring gap was just acceptable: I would say that in another 80K I will need to replace pistons as the the gap will be too big by then. It would have been nice to lash-out for new jugs but as I'm also doing the gearbox, this will do for now.
Fitting the rings and inserting into cylinders was easy, I had them all installed and then I questioned the orientation of the piston dome. It became apparent after checking on Pelican that I had them upside down... so off they all came.
Its all good fun. :D
http://i79.photobucket.com/albums/j1...s/IMG_0622.jpg
See the 15mm copper pipe - using it to hold the cylinders on. Who needs the porsche tool?
http://i79.photobucket.com/albums/j1...s/IMG_0621.jpg
Heads are on - aren't they beautiful? :blush:
http://i79.photobucket.com/albums/j1...0639Medium.jpg
http://i79.photobucket.com/albums/j1...0638Medium.jpg
Chain covers on next. You may be curious about the nice colour of the aluminium chain covers?
Well - you know your alloy wheels? Most wheels are painted - with silver aluminium paint. So are these parts! It will stop them from tarnishing and for now they look cool.
http://i79.photobucket.com/albums/j1...0636Medium.jpg
http://i79.photobucket.com/albums/j1...0637Medium.jpg
http://i79.photobucket.com/albums/j1...0641Medium.jpg
http://i79.photobucket.com/albums/j1...0643Medium.jpg

When it came to fitting the cam sprockets, I notice wear on the teeth of the right bank sprocket. So I decided to replace this plus the chains.
http://i79.photobucket.com/albums/j1...0667Medium.jpg
http://i79.photobucket.com/albums/j1...0668Medium.jpg

I don't know what the manuals say about fitting the new chains? I broke the old chain, tied a link of the new chain onto the old and pulled them through. :closedeyes:
http://i79.photobucket.com/albums/j1...0669Medium.jpg
http://i79.photobucket.com/albums/j1...0670Medium.jpg
All the parts (most of em) came from Pelican Parts, including the "Super fastner kit", which includes every nut and washer you need to do the motor.
http://i79.photobucket.com/albums/j1...0671Medium.jpg
http://i79.photobucket.com/albums/j1...0672Medium.jpg
http://i79.photobucket.com/albums/j1...0673Medium.jpg
Stick the fan on - with the same treatment as the timing chain boxes. In case your wondering - I spent or the parts spent days in tubs of varoius chemicals soaking off the gunk, before blasting and then priming and topcoat with proper alloy wheel finish.
The fibreglass fan shroud and other bits got hit with a burgandy colour, which just happens to be the colour of the interior (cabin).
http://i79.photobucket.com/albums/j1...0681Medium.jpg

http://i79.photobucket.com/albums/j1...0682Medium.jpg

To anyone contemplating such a project the main advise I can give is get totally organized. A good friend lent me a complete shelving system (industrial), which I totally covered all 6 shelfs (4mts x 1.5mtr each shelf) with parts, etc. It may seem trivial but this makes such a differance. Plus, my shed is a big shed. Apart from that, its just tools and time. By the way, if anyone ever needs the tool for setting the cam/chain timing, I had one made, and your welcome to borrow it. Without this tool it is impossible to do.
As the car has been off the road for a while now, I have completed a few other tasks, such as restore the oil tank.
Photo below is the tank totally stripped and clean.

http://i79.photobucket.com/albums/j1...0635Medium.jpg


Then, painted with POR15, (which I use all the time) and then sprayed with primer, then painted with black engine enamel.
http://i79.photobucket.com/albums/j1...0691medium.jpg

So, the story continues:
You say "What now"?
OK?
The inlet side of things...?
I just couldn't help my self.
http://i79.photobucket.com/albums/j1...0683Medium.jpg

http://i79.photobucket.com/albums/j1...0684Medium.jpg
I was going to polish the aluminium manifolds: you can see I started to, but these parts are sand casted and hence pretty rough. So I decided on the paint option, POR again, primer, and black engine enamel.

http://i79.photobucket.com/albums/j1...0685Medium.jpg

http://i79.photobucket.com/albums/j1...0686Medium.jpg

http://i79.photobucket.com/albums/j1...0687Medium.jpg

http://i79.photobucket.com/albums/j1...0688Medium.jpg

http://i79.photobucket.com/albums/j1...0689Medium.jpg

http://i79.photobucket.com/albums/j1...0690Medium.jpg

With all the inlet in pieces, it was so easy to check hoses and injectors.
And of course strip and paint anything that moved? :blink:
http://i79.photobucket.com/albums/j1...0701Medium.jpg

http://i79.photobucket.com/albums/j1...0702Medium.jpg

http://i79.photobucket.com/albums/j1...0703Medium.jpg

http://i79.photobucket.com/albums/j1...0704Medium.jpg
Injectors, complete with new 'O' ring kits. See later photos for details.
http://i79.photobucket.com/albums/j1...0705Medium.jpg

http://i79.photobucket.com/albums/j1...0706Medium.jpg

Them injectors? or solinoids?
Things that squirt hydrocarbons into the heads.
They simply plug into the inlet and fuel rail?
Here's one, stripped with kit, along side. Top one is complete with old bits.
Note the 944 part number.
http://i79.photobucket.com/albums/j1...s/IMG_0699.jpg

Well with the motor basically finished (its now sitting on a shelf), just needs plugs, new clutch disc, oil & fuel.
So I have now started on the 915 gearbox.
http://i79.photobucket.com/albums/j1...0711Medium.jpg
Straight in to it... no mucking about... just rip the bloody front off.!
Christ...! Look at that? Its full of gears?
http://i79.photobucket.com/albums/j1...0715Medium.jpg
Take all this junk off?
Pulled these axle things off?
http://i79.photobucket.com/albums/j1...0716Medium.jpg
http://i79.photobucket.com/albums/j1...0717Medium.jpg


And then this bloody great heavy thing fell out?
http://i79.photobucket.com/albums/j1...0719Medium.jpg


But - I knew there was some wear in the box. Have a look at the two drive axle bear shells in the next photo.
I have put them face to face so that a comparision can be made. Note the wear?
http://i79.photobucket.com/albums/j1...0722Medium.jpg

These are to be replaced. The diff it self looks fine.
To get some help on further exploration, I posted the following question on Pelican.
http://forums.pelicanparts.com/showthread....328#post2617328
Its always a helpful site, and so it was this time.
The result from this posting, is Mike from MB Engineering http://www.mbporsche-engineering.co.uk/
has offered his assistance. Which means a ferry trip for me across to Kendal for the day, to watch Mike put my box back together again. The part I was concerned about was the pre-load on the diff - as I am replacing the pinion bearing this will be changed (pre-load) - and this takes some serious measuring.
More soon.
PJB

I'm looking at the photo in post number 5...

Man, that's the most stereotypical English looking garage I've seen! (Which looks kinda cool IMO.) What's that in the rafters? Radishes?

Here's what the typical U.S garage looks like.
http://forums.pelicanparts.com/uploa...1149203370.jpg

:D

Hillarious!!! We're a little cramped for space here in silicon valley - I never thought of storing produce in the garage....

(ROFLMAO)

Glad you enjoyed:
The shed I work in is probably well over a hundred years old! In fact it use to be a horse stable.
They are onions hanging in the background, we grow our own veggies. In another corner there was a big box of potatoes.
Each to his own.
Peter

Great Photo documentary! Great work, too!
Good luck with the rest of your project!

Doug

Yes, great work! Sorry, I'm easily distracted by anything remotely humorous.