Preparation
 

Here's the engine all cleaned up (thanks for helping Dave) with the injection pump temp installed.

http://forums.pelicanparts.com/uploa...1216957287.jpg

The car is ready to accept it's engine back.

http://forums.pelicanparts.com/uploa...1216957319.jpg

Installed front wheels today.
They look shiny, metallic...and restored.

http://forums.pelicanparts.com/uploa...1216957342.jpg

looks fantastic :) im jealous!

911 Sandrail
 

This is interesting. Someone put a 2.7 S engine in a sand rail.
Check out the oil tank on the right with it's filter mount. Also you can see the Bosch MFI pump on the motor. Sheet metal Cad plated? LOL Good idea.
What kind of air filters are those?
I'm sure it sounds awesone but this motor might be more proper inside a beautiful 911 ;).

http://forums.pelicanparts.com/uploa...1217168896.jpg

http://cgi.ebay.com/ebaymotors/72-73-PORSCHE-911T-911-T-2-4-2-7-INJECTED-ENGINE-MOTOR_W0QQitemZ120285312737QQcmdZViewItem?hash=ite m120285312737&_trksid=p3286.m14.l1318


http://forums.pelicanparts.com/uploa...1217168942.jpg


I'll be back from No.San Diego tonight. Usually I can't work on the Carrera on weekends because I visit my Uncle who has been very ill.
I think that it's important to be with the one's you care about because one day they won't be there to visit.

those air filters look like k&n with the optional precharger filter wrap covers;
http://www.knfilters.com/universal/universal.htm

and the wrap;
http://www.knfilters.com/wraps.htm

When are you guys going to meet up again?

David

hey guys, i'm going to be in los angeles to help a 951 buddy with a motor rebuild. it would be great to meet you all if it works out. in any case i'm definitely planning on making at least 6 laps on mulholland, though it will be in a crappy chevy cavaliar econobox (loaner).

i'll be there during august 12 through 17th.

Mulholland
 

This is an old orange crate label from up north.
Nice graphics for an orange crate.

http://forums.pelicanparts.com/uploa...1217341712.jpg

I was out in Thousand Oaks for work and stopped at Enrique's for lunch. Finally caught up with Henry (HPV). Great guy to talk to. Lot's of Mulholland, San Fernando Valley and racing memories. Spoke of Dave (TRE) and Victor (SSB) like it was yesterday. (wasnt it?). He has a great establishment and great food. Layed back atmosphere and bar with awesome racing photos everywhere. Big fan of
917's. I wish I could have stayed longer. Thanks Henry!

I was out that way as well. Stop following me!


DavidI: All's quiet on the driving front.

What do you say we make plans to meet while nize is in town. What day works best? The 15th is a Friday so after meeting on Mul we could drift down to Bob's for some hot rod action.

Porsche Mechanical Fuel Injection Lines Cleanout
 

The Porsche/Bosch manual recommends Chemtool for the MFI unit's lines and other parts.

http://forums.pelicanparts.com/uploa...1217467016.jpg

It took a couple of days to locate Chemtool in a spray. It's sold out in most places, it must be good.

http://forums.pelicanparts.com/uploa...1217467039.jpg

I noticed that the orifices of the injection pump side of the fuel injection lines looked clean.

http://forums.pelicanparts.com/uploa...1217467074.jpg

It was the injector side of the lines that looked dirty. At first I thought that it was rust, but Dave convinced me that it was dirty laquer.

http://forums.pelicanparts.com/uploa...1217467092.jpg

Porsche Mechanical Fuel Injection Lines Cleanout
 

Berrymans Chemtool was sprayed thru the lines from the "pump side" of the lines

http://forums.pelicanparts.com/uploa...1217467673.jpg

After spraying each line three times with a continuous blast of Chemtool, the lines were left to drain for 30 minutes.
Then I sprayed Chemtool from the other end of the fuel injection lines.
Then the process was repeated.

http://forums.pelicanparts.com/uploa...1217467693.jpg

Whatever resins were in the lines were cleaned out after using the Chemtool.
You can see it as a dissolved gasoline ooze on the rag.

http://forums.pelicanparts.com/uploa...1217467713.jpg

After two cleanout routines using the Chemtool, I used compressed air to eliminate any traces of solvent in the lines.

http://forums.pelicanparts.com/uploa...1217467763.jpg

After I was done, I felt that the whole process should be repeated again for safety's sake.
It was a good thing I did it again.
More junk came out of the lines, and after completion of a second process, the lines blasted air out cleanly without any residues or obstructions.

They are ready to re-install.

Motor goes back in as soon as MFI pump is timed and cylinders are checked and lubed.

Good to see. I still think we can make those lines shine...

Porsche Mechanical Fuel Injection Lines Cleanout
 

Thanks Dave.
Maybe when I find my extra set of Bosch MFI lines they should be "Black Chromed".
They could be put onto the engine easily.
What do you guys think?

I would not coat the lines with anything. Leave them naked or shine them up.
You want them to stay as cool as possible. They already absorb heat from the pump.

Perfect example is when the the Datsun Z went to fuel injection the lines were coated with black vinyl and resulted in fuel vapor problems. Instead of using bare lines to remedy they added a little blower fan to keep the lines and injectors cool.

Porsche race cars used plastic lines instead of metal for very good reason. The MFI uses very high presure and vapor issues should not be an issue. Doubt your car is going to that hot but why take a chance?

The Pole Workers Union motto: when it gets hot go naked!

Piston and Cylinder check
 

I was talking to my friend Mike Flannigan this morning about how to effectively spray the cylinders.
Mike is a Dodge mechanic in Van Nuys and used to be a jet engine mechanic for the U.S. Air Force.
He came over with this tool to illuminate the combustion chambers of the Carrera's motor.

http://forums.pelicanparts.com/uploa...1217529140.jpg

There is a long wand with a bright light on the end. It is very thin and will fit easily into a spark plug hole.
In this photo you can see that two of the spark plugs have been removed.

http://forums.pelicanparts.com/uploa...1217529159.jpg

After removing all the spark plugs I was able to individually see the piston top and the bottom of each cylinder wall.

http://forums.pelicanparts.com/uploa...1217529178.jpg

It's difficult to see, but with the wand inserted into the spark plug hole, the entire combustion chamber is lit up (with the piston at bottom dead center).

http://forums.pelicanparts.com/uploa...1217529195.jpg

All pistons had a light coating of black carbon on their tops.

The cylinder walls were clean, smooth, and had no visible corrosion.

Randomly, I was able to inspect the underside of some of the exhaust valves and their seats.
They protrude into the combustion chamber on the engine's exhaust stroke and are easy to see, they appeared as new.


One cylinder had oil inside of it laying like a dark green lake (Kendall GT-1).
All of a sudden it dawned on me why the engine wasn't turning over at the time when I prepared to remove the engine from the car.
Oil had back-drained from the large capacity front oil tank (16 quarts) to the engine in the rear.
When the crankcase got too full of oil, it seeped past the rings from the "case side" of the pistons and into the combustion chamber.
That's why the headers were full of oil, same reason. Oil had made it past the rings and into or past the exhaust valves and into the headers.
Another good reason to start a Porsche frequently (along with MFI damage, water condensation damage, etc).

So I took a long cloth to wick out any remaining oil in that cylinder, we don't want to possibly bend a rod.

Some final pieces and details
 

Yesterday afternoon, I went to TRE to say hello and ask a couple of questions about spark plugs and engine oil viscoscity.
Jeremy was out but showed up soon after I arrived and was very helpful.
Dave B. showed up a little after that and was able to answer my spark plug question completely.
I was looking for Bosch W280 P21 spark plugs. No wonder I couldn't find them, they have been superceeded with Bosch W3D P0 spark plugs.
Dave said that's what everyone's using in their RS and RSR cars. Thanks Dave!

My old plugs have very low mileage on them especially for being over 30 years old.

This brochure on Brad Penn Racing Oil was very informative.

http://forums.pelicanparts.com/uploa...1217638729.jpg

Here is the history right here showing that Brad Penn is basically Kendall.

http://forums.pelicanparts.com/uploa...1217638762.jpg

This is some more very interesting information.
I'm sold!
It's the same oil that I've been using for 32 years. If only I could find the same tires... ;)
Jeremy gave some help in the tire dept. Thanks Jeremy.

http://forums.pelicanparts.com/uploa...1217638779.jpg

One more important detail, Jeremy helped by having the aluminum sealing washers that fit under the fuel injectors.
You could re-use the old ones possibly. I read that by heating them in an oven you can recondition them.

When dealing with the MFI system, I think that it's always a good idea to stay clean and use new gaskets and seals.
Thank you again Jeremy.

Here is a picture of the old injector seals.
Even slightly out of focus, you can see that they have already been seated and need replacement.
The fuel pressure at the injectors is very high, sealing is very important.
(The injectors are attatched to each cylinder head near their own respective intake port).

http://forums.pelicanparts.com/uploa...1217638803.jpg

Chris you could heat the old aluminum rings and make them sot again, but they have already flattened and will not puff out again. This is where the problem is.

MFI Prep
 

After lubing the cylinders with light oil I checked rotation.
The engine turns over easily with a 17mm wrench on the crankshaft pully (spark plugs out).
There are NO hard spots.

The fuel injectors were checked on the machine by Robert at Jerry Fairchild Industries when the MFI pump was being refurbished.
All are within normal parameters but could use a fuel additive in the gas tank to clean them fully.

http://forums.pelicanparts.com/uploa...1217984002.jpg

Here they are installed on the motor.

http://forums.pelicanparts.com/uploa...1217984025.jpg

This is a close up shot. You can see the little red plastic booties that Jerry Fairchild Industries puts on both the injectors and the MFI pump connections to protect them from contamination before final assembly. Very Nice!

http://forums.pelicanparts.com/uploa...1217984042.jpg

Can someone get this thread moved back to the technical forum?
This is good stuff!