Dad's 911SC - I am finishing rebuild (long)

[Robey5]

I installed the alternator/fan assy last night.

There is a large label (mine is gold in color, BLING!) on the top of the steel "strap" that holds the fan housing in place. What is this label? What is it supposed to say? I am assuming this is one of those things that says "point gap is to be = xxx" etc.

Can I replace it with a new one? It appears to be just a foil sticker. Where can I get a sticker to replace this? As I am not really doing a "period correct" restoration - I suppose that I am open to something a little different there - provided it will not be too much work to put there.

[Robey5]

Today - I invested my "lunch hour" (as if that actually exists) and worked on the CIS system in the workshop here at the office.

My intent: pull the injectors to mail them to get re-conditioned and restored.

Wow; I wasn't ready for what I encountered. On the #6 cylinder, the injector basically came out; no pulling force was needed. The O-ring was there, but I think that I am missing something in that aluminum intake runner pipe. All 5 other injectors took a LOT of effort to pull out, and I had to pry them out.

Which brings me to my question: What is this retention device? Can I buy/install new ones?



The O-ring broke here....





Finally - there are protective lines over the fuel lines and various other connections. The hoses themselves are not damaged; but the protective lines cracking all over the place. Any suggestions for what to replace these protective sleeves?

[Robey5]

Image #1 in the post above: is this the "injector sleeve" part number 911-110-886-03-M260???

If so, I will replace them (...all 6 of them). I was searching some of the tech-articles on fuel injection and I did not see how to replace this item.

[Robey5]

Moving along, slow but steady.

Today, after a LOT of interweb searching: I decided that the injector sleeves, sleeve O-ring, and the injector O-ring would be purchased. Host contacted, order placed.


In a moment of curiosity, I pulled (...removed... or - more accurately - destroyed) 1 of the sleeves. This thing is plastic (thought it was brass alloy - NOPE), was brittle, spun around until I was able to get a punch to stay on the sleeve and push it out of the port. This thing looks like hell, and I bet this was an air leak source on the intake.

This thing looks like a turd (the spent sleeve).






Am I missing something - I cannot seem to find a tech-article on how to replace the injector sleeves on my CIS system.

[Baby]

Some good threads right here about the process. Looks like you ordered all the stuff you'll need. The sleeves are held in by stents. Best to read up on the options for removal in case yours don't all crumble!

[James Brown]

yep easy, they just slip in and the injectors are held in with the o ring, they are a source of vacuum leaks

[Robey5]

The CIS air box is trashed. I am trying to figure out which one I have because I have conflicting measurements and would like to buy a better sample. When I measure the intake runner diameter (the ID of the cast aluminum runner where the rubber sleeve goes to connect to the runner) I am pretty consistently getting around 38.5-38.8mm. The OD on the machined area of the runner is a little closer to 45mm (44.60-44.89). The part number cast into the runner is 911 110 1694R. There is a date code cast into the side of this particular runner that I pulled off of the system says 78/12.

According to the parts catalogue, I *should* (according to my model year) have a "large port" air box (44mm diameter) - and the evidence cast into the parts lead me to believe that this is so, but the measurements that I have made lead me to believe that someone put a different year CIS system on the car for whatever reason (which would not surprise me considering some of the other work I have encountered in my journey thus far.)

I turn to the forum for input. 44mm is measured where? I am going to post a WTB classified for a reasonably priced air box, but need to know which one to "request". Model year and cast in dates have me leaning toward the model year correct box (44mm) - but measurements have me questioning myself.

[Robey5]

On Saturday - I was able to spend a little time with the engine. I think that I am about as far as I can go before the intake and exhaust system go on.

Because I like pictures, I will take the liberty to post a progress shot. [enjoy]






Still have unsure which airbox I have, the intake is getting worked on and installed next. I will be headed out of town for a little while - I would like to get the airbox purchased and en-route so that I can pick up with the repairs when I am back in town.

[Robey5]

More disappointment this evening, as I found another broken part while working on the CIS preparing for the new injectors/sleeves/etc.

It appears that there has been some welding on the #4 and #5 intake runner. Ok, so the one on #4 was a little obvious (welding can be seen on the outside), but when I looked inside the runner, the job was cleaned up somewhat nicely, and I am OK with it. I then took a closer look at the #5 runner, and it is really not looking healthy. Now as I get further into this project I am starting to think that Dad was on to something by having let this beautiful machine sit in pieces.

Anyhow, I am going to take this to a welder (tomorrow) to see if he can make it useable again, otherwise I am going to have to replace it. I am thinking that there is a WTB post in my very near future.



Any thoughts here? Is it salvage-able?

[911 tweaks]

anything is salvagable...just depends on how far one wants to go...regarding this part, it is the intake runner, so, as long as it does not leak air & the bottom is flat so it seals w/ a new gasket, you will be fine...so, weld it or jb weld it or some how make sure it does not leak air & you are good to go...making progress every day is what it is all about...carry on... :-)

[Lapkritis]

^Agreed - a competent tig welder can fix the crack. A machinist can belt sand the base flat after if needed. No big deal. Almost there!

[James Brown]

should have no problem finding CIS parts, i had a bunch lying around somewhere. Good part is there aluminum and easy to weld, light torque on the intake nuts on reassemble.

[Robey5]

Ok guys - thank you for 'reelin me in' about this.

I was looking at the prices for a new one of these from our host and was quite concerned...

Off to make a couple calls to some peeps who can weld.

[euro911sc]

its probably cheaper to just get a used one.... they are in abundace.

[Robey5]

Just got back from a ride vacation out west - I was greeted with a couple boxes when I got home (sweet).

These boxes had the injector sleeves, sleeve O-rings, and new injector rings.
In addition to these misc CIS related parts - I purchased the rubber hoses that connect the air box to the aluminum runners, and determined that I indeed have the 44mm (big port) air box (which is model year correct) - by using the old fashioned method of buy it and hope it fits. Good times.

In addition to these parts, I also received another box, containing a braided SS vacuum line, as well as some protection looms to put over the fuel lines.

Time to break out the bill fold (once more) to get a new airbox.

[Robey5]

I got a couple of hours to work on the CIS tonight.

I have a little case of "while I'm in there"- itus.

So - what is this? It is located behind the airbox, and connected to the throttle-body. I don't think it is broken, just the hoses are a little worn. Looks like there is air going through this device at certain times - another potential problem due to 'false air'.

Could the hoses be replaced only?

[GaryR]

I would replace those, much easier to do it now!

[911 tweaks]

the hoses may not look too bad now, BUT, wait till you compare the old hoses to new ones...!!! I bet you find the old ones about to let go or may have cracks already at hose ends...
Also, it is possible that when re installing parts a/o an engine that some ones hand grabs this area a/o it rubs against something or such which then cracks them and you would probably never know because they look old then as they look now...
New flexible & supple hoses can with stand a bump, flex, ect...you get my drift...

[Robey5]

Looking at the PET system - this metal part looks like a "vacuum limiter" (the metal part only) - however, the car is not original - and it looks like it just 9X2.5 hoses that have been modified so that it is not going to the exhaust/air system.

Eeerrr... I am not really sure what to do with these things; do I just buy some 9mm hose with the cloth covering and replace?

[Robey5]

Cloth covered hoses purchased. Oddly - they show (in the PET dwgs) that there is one hose 190mm in length, and the other at 110mm in length. However; our host only has one size -- 190mm.

So; I am just going to take a slight gamble here and think that there was a hack who didn't want to replace the hose, so that is why there is a 90 elbow on there. And... (911 tweeks) you're correct - the old ones were dry as a bone, cracked; melted and whatever - they need to be replaced.

This CIS system is going to be 'factory fresh' as far as the rubber hoses and injector seals are concerned....

I am not going to say (even for a second) that I am the most skilled wrench, but I am a little disappointed in the amount of pride and patience that past wrenches have executed on this fine machine. This is just the engine. When I go pick up the car (in a couple weeks) - I am sure that I will encounter more interesting nuggets POs have left behind.