After 1000 miles, 100 man-hours, and 100 days it's finally going home.......

[boyt911sc]

Sometime in early spring of 2011, a young Pelican parts member (whom I've never met before) showed up at my door step with his engine that needed some work. Several days before this date, I offered to help him rebuild his engine but the problem was the vast distance between Madison, WI and Philadelphia, PA. However, he decided to drive over 1,000 miles and delivered the motor to my place.

Since I play golf almost everyday during the week, I offered to do it on my free time and needed 8 weeks barring any unforeseen set-back. Everything seemed to be in schedule until the re-assembly of the engine started. Two (2) of the 6 piston oil squirters were found to be defective. Reviving them to work again was unsuccessful and had to be drilled out. So the engine re-assembly continued. Cylinder #3 was severely damaged at the area where the gasket sits. A replacement single unit was located after a search. Then the left side chain housing had a missing stud that holds the chain tensioner. A replacement housing was located too. While everything was going great (I thought), the timing cam flange for the left bank was discovered during cam timing to have a hair-line crack on one of the sprocket teeth. The tooth broke off during the process of setting the cam timing and could have been disastrous if not noticed by accident (luck).

1st week:


2nd week:


3rd week:


4th week:


6th week:


7th week:


8th week:


9th week:


The top and bottom end rebuild was completed by the 10th week and spent the next 2 weeks doing the CIS troubleshooting and engine start-up. The engine is running now and done with the engine break-in. The owner (Dave Santana) will be coming next week for the pick-up. I will surely miss this engine after sitting in my work place for 3 months.

CIS troubleshooting: Vacuum leaks were located and corrected. Fuel injectors were bad and leaking. Replacement injectors (refurbished) installed. As of this writing, one known problem that has not been corrected is the missing ground for the mixture control unit. The engine ran the very first time it was started and the joy of hearing the motor run was priceless. I wouldn't have done this without the unselfish assistance of some members.

I would like to express my thanks to Bruce Abbot (Flat6pac), Mike Bruns, and Glenn Sager (Pelican parts sales) for their help and valuable advises. Without them, I wouldn't be having such a good time doing this kind of hobby. Need another project for the fall season.

Tony

[pete3799]

What are you doing after your next round of golf?
Nice work Tony.

[Flat6pac]

I like the running setup, Tony, but how do you create load as in driving the engine?
Bruce

[boyt911sc]

Originally Posted by Flat6pac

I like the running setup, Tony, but how do you create load as in driving the engine?
Bruce

Bruce,

The engine test stand was fabricated primarily to facilitate troubleshooting. With the engine installed in the car, it is almost impossible to work the backside of the engine. Looking for vacuum leak, fuel leak, and others are very convenient with a set-up like this. It saves a lot of time and effort to install a tested engine that has undergone a complete engine rebuild in a car knowing that everything is OK. Just plug and drive.

With this set-up, I could pressure test the fuel lines and run the engine while I closely look for any sign of fuel leak. Vacuum test takes a minute to complete. Valve adjustment under 15 minutes. This motor is ready for installation and a drive around the block.

Secondly, the owner won't be calling me later that the newly rebuild engine does not run or won't run at all. I have taken a few video of the engine running both from cold starts and warm starts.

Tony

[boyt911sc]

After spending more than 100 man-hours the last 3 months rebuilding this motor, the newly rebuilt engine is finally going home to its rightful owner (D. Santana aka papapapa). The owner arrived today and took it home after a long over-night drive from Madison, WI to Philadelphia, PA.



The motor ran flawlessly during the break-in test run. All it needed now is a car to house the engine. It has created a vacuum (space) in my work place. So I have to look and search for another project for the fall.

Tony