Assessing feasibility of DIY 2.2T top end

[deathpunk dan]

Hello

I've got an unstamped replacement case engine in my car now. It leaks and make flat power. After talking with an encouraging PP board member, I am considering trying to tackle some or all of a top end rebuild on a 2.2T.

1. I am leaning towards having the existing iron oem cylinders bored to 86mm. For street driving (I am thinking ~9.2 compression at most) with no more than E or Solex cams, are 86mm AA pistons sufficient? Is the ~$500 delta for JEs worth it?

2. What should I expect to pay to have the heads rebuilt to stock spec?

3. How can I determine the viability of not splitting the case? How do I know the bottom end is good? Pull the barrels and check for rod play? How much is too much? Remove the sump plate and check for metal filings? I have been told the T is so under-stressed the bottom end is usually good to go.

4. Should I assume my HEs are no good? The outer pipes are pretty solid, but I have no idea about the internals. These are not SSIs - but regular early style OEM HEs.

4. Beyond the gasket sets and new timing chains, what else needs to be done? I have a complete set of 3.2 tensioners including the oil lines. I also have a set of rebuilt Webers, a nice E distributor etc.

I have the engine rebuilding book, but loaned it to someone who seems to have misplaced it. I appreciate your patience. It's certainly possible I start collecting parts and farm out the assembly and tuning, but I want to know if my plan is solid for the intended use of the car (street driving, budget minded build)

[tharbert]

I'm an enthusiast, not an expert. I am doing a refit/mod of my 72...

1. Can't answer about the P/C selection except that you need to look at them as part of a system. For instance, JE pistons require different cylinder fitment specifications to Mahle. If you have cylinders bored, they need to match your choice of pistons.

2. There are a number of good shops around you who do Porsche heads. I had Anchor Atlantic do mine and they are works of art. Call any one of them for quotes but be aware the cost will change significantly base on the shape of your heads. I needed all new valves in addition the normal bits/pieces and machine work.

3. Ah, here's the $2500 Mag case question. Maybe an expert will chime in concerning the rod journal specs being predictive of the rest of the internals. All I can add is that my 2.4T crank was knackered. Had I continued without splitting the case, I doubt it would have made much oil pressure.

4. HEs: If this were my limited budget project, I'd save this question for later. You can always bolt up a new(er) exhaust system when you get around to it. I've been watching for used HE's and not a single set has appeared that didn't look like they were crap.

4 (5). Again, this is an enthusiast's list, not an expert one: chain ramps, oil restrictor, rocker shaft seals, oil return tubes, modify engine tin, clean/test oil cooler... My guess is that Wayne's 101 book may have a pretty comprehensive list of what you should/could do with the engine out.

Good luck!

[Matthew Barnes]

+1 on Wayne's Book. Get yourself another copy (and send the bill to the forgetful friend!).

Most of the questions re bottom-end wear etc are answered. A old pro will also be able to give you signs that the bottom needs a look. The T crank is pretty strong, I know of a few racing chaps here who like the T crank in the bottom of their racing engines due to it's strength. But who knows what the bearings look like in yours.

Not sure about costs for rebuilding heads in the US but a search in this section should give you a rough answer. The rebuild wizard on this site will also give you an idea of the parts cost: gaskets, chain ramps etc etc.

[deathpunk dan]

Not only did I order another copy of 'How to rebuild and modify Porsche 911 engines', but i also picked up a 911 engine assembly book.

Some downtime over the next 2 weeks will be spent reading, re-reading, taking notes, making lists etc.

Thx

[bgyglfr]

Hey Dan,
It's a long winter. Why not tear into your engine and post here as you go? It won't be the first time this forum walked someone through a rebuild. If you build it yourself you will know exactly what you have.
The best of luck,
Kirk