x-faktory 2.2T rebuild

[al lkosmal]

I've been busy today........dropping the engine out my friend Bob's 71T........time for an engine rebuild...going from a stock 2.2 T to a 2.2 E/S. 40mm PMO carbs, Mahle 9.8:1 P&Cs, E-cams, Headers, Sport muffler, etc.......should wake this one up a little. This engine was rebuilt approx 8 years ago and according to the owner "hasn't felt right since". It had been rebuilt by an infamous builder in CA..........initials are/were MM...(and it's not Mickey Mouse, but most of their work was.)
I'm looking forward to the tear-down on this one....who knows what we'll find in there.

[Trackrash]

2,2 is one of the sweetest motors Porsche ever produced. I will be interesting to see what is inside this one.

[RSBob]

I predict you will find in the engine a little man with a big hammer

[al lkosmal]

Originally Posted by RSBob

I predict you will find in the engine a little man with a big hammer

Being a little man with a big hammer......I should be able to recognize another one instantly.

regards,
al

[al lkosmal]

This engine was rebuilt approximately 3000 miles ago by the infamous MM.

Here are my comments, observations and supporting pix related to the engine teardown/analysis:

1. 3 out of 6 exhaust valve are covered with oil....appears to be leaking valve guides...so likely worn valve stems/guides. ...not likely these were installed new, 3000 miles ago

2. one piston had an impression in it (looks like a washer was left in the cylinder)

3. Rod small end bearings are worn a bit and need replacing

4. Rod large end bearings are totally toasted....this could be due to dirty oil and/or machining debris or media blast debris not cleaned out during the last rebuild.Also can be caused by poor oil supply.

5. Main bearings are also very worn.......

6.The crank also has some scratches, due to the bearing wear....They don't catch my fingernail, I'll be taking it to have it magnafluxed and micropolished.....I'll have them inspect and decide if the scratches will polish out.

7. Cams look pretty good. Journal bearing surfaces have slight scratching. Doesn't matter as we'll be installing new cams

8. I measured piston and cylinder #1...the cylinder was oversize (out of spec) and the piston was quite a but undersized and oval (out of spec) Basically these are not parts with 3000 miles on them...They have many miles on them.

9. Both tensioners were collapsed.....luckily there are guards installed.

The bottom line take away.......I've seen 911 motors with 200K miles with less wear......there is definitely evidence of a rebuild, but it was not done with new parts....

Check out the pix.........this was rebuilt by MM 3000 miles ago.....

[al lkosmal]

more pix......

[blee]

I'm sure Bob will notice the difference this time around - that motor does not look rebuilt! Those bearings look terrible.
He's in good hands now - the X-man's!!!

[al lkosmal]

Brian,
Yep...another MM disaster.....this engine is very worn out.....they really took advantage of a lot of people.....it looks like it was re-ringed, cleaned up, resealed and put back together.....I took the oil pump apart and found what looked like plastic media in it. (I never have the case or any moving parts media blasted....it is just clean dirt that gets everywhere and a total pita to remove).......however....just shipped the heads (rebuilt and ported), rods & rockers (rebushed, rods balanced) off to Craig Garrett. Crank will be dropped off for magna-fluxing and hopefully it can be micro-polished back into great shape......new Mahle S pistons and Cylinders, E-cams, 40mm PMO carbs (yes I said carbs) SSIs and sport muffler....also installing a Rennshifter.....this is a very, very sanitary 71T...same owner since 1973 and it deserves some proper moto-vation!

[911SauCy]

I am astonished at the bearing wear... I've seen 250k mile motors and the bearings still look new (relative) but that's incredible...

[al lkosmal]

Heads have been rebuilt, rods balanced, etc by Craig Garrett. Here is his report on the condition of the parts......

"Did you have a chance to run this motor and notice what the owner said about it never felt right since the rebuild? (by MM)

I noticed a few things, the valve guides were fine, just undersize to match the warn out valve stems. I honed them to spec without any issue.

The seats varied in width not matching the valve in most cases. None showed a three angle cut to promote proper flow.

The rods, although total weight within a couple grams of each other the large ends varied up to 14 grams and you will notice one rod had a lot of material removed to bring them all within one gram of each other. "

So, in addition to the very worn bearings....as suspected the heads/valves/rods were also AFU.....I can't wait to put this back together and bring it back to life.

[al lkosmal]

Well, i received the heads, rods and rockers, back from Craig Garrett. Heads have been rebuilt and ported to S specs, rods rebushed/balanced and rockers refaced/rebushed, etc.....As usual, Craig's work is top notch and the rebuild is underway.







regards,
al

[jimtweet]

Great work as always

[al lkosmal]

thanks Jim....appreciated....

[RSBob]

Too me it looks like you are trying to asphyxiate the poor thing. Rather twisted. And, your welcome.

[al lkosmal]

Originally Posted by RSBob

Too me it looks like you are trying to asphyxiate the poor thing. Rather twisted. And, your welcome.

Rick,
Glad you noticed....the engine appeared to be in an advanced state of excitement....so I had to take appropriate measures.

[Reiver]

Great story....the 'Red Fan' disease.... 'Hey, but the price was right!'...I remember their adds in Panorama. What a scam factory and they ran for awhile before getting nailed. Didn't that outfit re open under a different name?
I wonder what the Meister invoice to owner looked like....

Nice to see that classic lump get it's due....

[al lkosmal]

Mahle 911S P&Cs are installed. Starting to look real!

[al lkosmal]

Reiver,
I remember those adds in panorama......smoking deal......and now they're just smokin....I did read that the former owner of MM opened a new shop.

regards,
al

[al lkosmal]

2.2 on the test stand....1st fire-up is soon..........



regards,
al

[blee]

Vi-de-o! Vi-de-o!