Long Block complete!
 

After many months, my long block is finally complete. I feel really good about everything to this point, besides it taking me so long to get things done right. I did hit the slippery slope on this project, but didn't fall all the way down.

Originally I dropped the engine in my 1987 Carrera to "fix a few leaks." That was at the end of February (yes, 2007). Heh. it was leaking from just about every usual suspect. Lots of sensors, the breather cover, the flywheel seal, you name it. 148k or so miles on the motor, internals have never been previously touched.

After I pulled the exhaust I saw so much buildup in the exhaust ports I knew I wanted to do the valve guides right then and there. John Walker took care of my heads and did a phenomenal job reconditioning them. Then, several Pelicans pointed out that I had Alusil cylinders. Henry Schmidt sourced me a set of low mileage Nikasils and a new set of rings, and also took care of balancing and reconditioning my rods. I split the case and had the crank cleaned up locally -- just needed a polish.

New main and layshaft bearings followed, as well as new chains. Sprockets looked good so I left them alone. I screwed up upon first attempting to join my case halves and wrecked the #7 main bearing -- one of the halves slightly rotated when I was checking the crankshaft rotation in the left side of the case, and I didn't notice cause of the assembly lube. It overlapped its mating half upon starting assembly and while I didn't damage the case, I did slightly ding that bearing which necessitated a pause for replacement. Unfortunately I didn't find a single set for an economical price in time (though I probably could have) and ended up ordering a whole new set...if anyone needs a set of 3.2 main bearings less 1 pair of plains shells for cheap, let me know. Case assembly then went smoothly using Threebond on the perimeter, Loctite on the webs. #8 glued in with Threebond silicone sealer as recommended.

P&Cs and heads went on without trouble. I got my cams reground to 964 specs by John Dougherty (Camgrinder) so that I could have a little bit of extra performance for all my trouble. See, slippery slope avoided! ;) Timing was not too hard either. Glad I have a metric dial indicator.

I replaced my alternator with a rebuilt unit as insurance; my fuel injectors were rebuilt by WitchHunter, which was good because they were pretty clogged up and had uneven flow. Let's hope they haven't suffered too much from sitting for six months like some others have experienced. I got the fuel injection system put together on my bench. I'm risking re-using the high pressure fuel line after close inspection. Yes, I know that could be a gamble.

http://forums.pelicanparts.com/uploa...1198198527.jpg


http://forums.pelicanparts.com/uploa...1198198339.jpg

Tonight I finished installing the cam oil lines, and wouldn't you know something bad (stupid really) had to happen. I overtorqued the right chain cover hollow oil bolt and snapped it. Luckily once that happens the tension on the bolt got released and I easily unscrewed the rest of it from the chain tensioner. I will get another one locally tomorrow and be careful to not be some ham-fisted when tightening it. I know better.

Otherwise, it looks good, and I only have to mate the fan shroud, fuel injection system, exhaust and engine tin, and then I'm ready to install! Feels really good.

I especially like this before and after shot.

http://forums.pelicanparts.com/uploa...1198198415.jpg


http://forums.pelicanparts.com/uploa...1198198362.jpg

I plan to have the car on the road by the end of the first week of the new year. And it might just happen!

Happy New Year !!!!!

Great job!

I really like the photos. Looks like a Nikon to me. But how do you get the lighting so good, do you just have really good lights in the garage? Or are you using a speedlight?

Looks like a Cannon to me:)

I'll bet it feels good, congrats!!!

Go to WitchHunter's website and read what he recommends doing on injectors sitting for a while. It may help you avoid a case of the stickies.

As far as the HP fuel line, I'll.......remain quiet!http://forums.pelicanparts.com/suppo...leys/sleep.gif

I use a Canon Digital Rebel EOS and a Panasonic Lumix digital point-and-shoot for most of my photographs. In general, I shoot with my flash disabled to get better color rendition. I do have a lot of lighting in the garage. Right over my "work bay" I've got a 1000 watt metal halide lamp which really lights things up. In my old garage I got tired of working in dimly lit conditions, so I went a bit overboard.

The engine is almost done and should go in before New Years. Let's hope and pray for the high pressure fuel line. I think it should be OK.

Thanks for all the help over the past ten months guys! I'll need a bit more for sure, but I really value all I've already gotten.

Preston,

I don't think you should be that concerned about the fuel injection supply line. The line you have there appears to be the factory updated line with the double crimp cups and NO swivels. The line you should double check is a shorty piece that connects the bottom of the fuel pressure regulator to the fuel tank return line. It's number 11 in this picture

http://www.pelicanparts.com/PartsLookup/HTML/911_USA_87_89_KATALOG/107-05-Frame3.htm

$175 is REALLY steep for this tiny piece. You can rebuild that section with a short piece of SAE 30R3 hose yourself or take it to a hose shop to have a new length of hose crimped on there. The price of the OEM replacement part would lead you to believe it's a preformed 90 degree piece of hose, but it's not. It's a straight length of hose that is turned upward to attach to the regulator.