Pelican Parts Forums - 930 3.4 Engine Rebuild (lots of pics)

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930 3.4 Engine Rebuild (lots of pics)

Hi Guys

I have decided to chronicle my engine rebuild. I performed a leak down test,
and discovered cylinders 1 & 5 were leaking 20% and 30% respectively.
Engine was running strong, but did make a phat phat phat sound.
I will be getting Mark Henry to do the heads for me. He will also be giving me a hand with the re-assembly.
Axles have been bungie tied, and I have a plastic bag around each hub.

Engine Out
http://forums.pelicanparts.com/uploa...1383521837.jpg

http://forums.pelicanparts.com/uploa...1383521899.jpg

Electrical wires disconnect
http://forums.pelicanparts.com/uploa...1383522022.jpg

http://forums.pelicanparts.com/uploa...1383522050.jpg

http://forums.pelicanparts.com/uploa...1383522099.jpg

Pressure Switch disconnect, Temperature Sensor disconnect
http://forums.pelicanparts.com/uploa...1383523592.jpg

I removed fuel distributor, throttle body, intake manifold as one assembly.
http://forums.pelicanparts.com/uploa...1383523698.jpg

http://forums.pelicanparts.com/uploa...1383523750.jpg

Throttle Linkage plate removal
http://forums.pelicanparts.com/uploa...1383523882.jpg

All head studs appear to be intact. Looks like 993 studs were installed at some point.
http://forums.pelicanparts.com/uploa...1383525412.jpg

Head Gasket Leak Cylinder #1 - 20% leak down
http://forums.pelicanparts.com/uploa...1383525482.jpg

Head Gasket Leak Cylinder #5 - 30% leak down
http://forums.pelicanparts.com/uploa...1383525516.jpg

http://forums.pelicanparts.com/uploa...1383525626.jpg

Let the cleanup begin. Clutch removed.
http://forums.pelicanparts.com/uploa...1383526383.jpg

http://forums.pelicanparts.com/uploa...1383526479.jpg

Getting ready for engine stand.
http://forums.pelicanparts.com/uploa...1383526530.jpg

Got my 2 neighbours to give me a hand lifting it onto engine stand.
http://forums.pelicanparts.com/uploa...1383526587.jpg

Exhaust nuts came off with very little drama. I mixed up some ATF and acetone.
Sprayed nuts, and let it sit for about 4 hours. Cracked the nuts with no issues.
Previous owner had used copper nuts. A few of the exhaust studs came out.
http://forums.pelicanparts.com/uploa...1383526821.jpg
Exhaust off
http://forums.pelicanparts.com/uploa...1383526859.jpg
Large crack on exhaust heater box. Need to get this checked out.
http://forums.pelicanparts.com/uploa...1383526932.jpg

Plan on removing the cam bolt and chain cases tomorrow night.
Question. Do most of you guys follow the Bentley procedure or Wayne's procedure?
The Bentley procedure suggests that the rockers for both intake and exhaust be removed. Wayne's procedure suggests that the valve lash adjustment screw be backed off. I guess I need to remove the rockers anyway. Let me know your thoughts. Also do you remove the cam towers with the heads?

Thanks

J

Also what is the best way to remove the tensioners? Compress the plunger. Lock 3mm locking pin, remove bolt. Remove assembly?

What kind of cylinders do you have there? Is it me or why there are no cooling fins?

Cylinders are Mahle 3.3 Turbo cylinders. Fins are on the bottom exhaust side.

Nice work so far JPilcher! You can back off the screws and pull the entire assembly off the engine without removing the rockers, etc. (heads, cam carrier, and all this little parts still attached) It is a little easier to remove everything and keep track of it while working on the bench. As for the tensioners, you probably won't get the pin in there until you are ready to reassemble. A little gumption and some finesse and you will be just fine. Keep track of the shims on the cam sprockets. Slow and steady wins the race. Do you plan on splitting the case or just a nice top end rebuild?

Tonight I went ahead and removed the rockers as per the Bentley manual.
Bagged and tagged the rockers. I will try and get some pictures uploaded.
Rockers were in not bad shape. Bronze guide had a little wear, but nothing too severe. Has anybody used the RSR seals?
My plan at this point is to do a full rebuild. I ve read a lot of horror stories
About top end rebuild that have gone bad.

RSR seals are a cheap and easy upgrade to prevent oilleaks from the rocker shafts. I sea no reason why not to do it.
Keep those pictures coming!!!!