Air box is blown..u would invest on a new one
And install the pop off valve. Things are adding up
Fast.

Looks like a blown air box. I would invest on a new one
Install pop off valve. Things are adding up fast.!

Timing chain tensioner supply line.

Was this original or part of an old carrera chain tensioner kit that was undone?

Yeah that cut off line should be feeding your tensioners. Will be interesting to pull the timing chain covers and see what kind of trnsioenrs you have....

I’d fix your airbox. Bolts/nuts will make clamping force. For the epoxy make sure you get something that bonds to ABS.

This is just me but I can deal with total scatter. Tearing down cis is fine but just do on step at a time or you might lose parts.


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CIS troubleshooting.........
 

Neil,

Your major problem is the cracked air box. No wonder you were having so much problem in troubleshooting. How many times did I ask you to do a smoke test? Re-seal the are box using either bigger metal screws or nuts & bolts. And pressure test before installation.

The air flow unit’s gasket is primarily a dust shield. Even without a gasket, it would not affect your CIS. Why? The AFM is under atmosphere condition like the air filter. The gasket comes in different materials (foam, paper, or cork).

The oil line by cylinder 1-2-3 is for a Carrera hydraulic fed tensioners and was modified/cut to work with your engine. I don’t think you have a Carrera 3.2 tensioner installed now in your motor.

Could you post a picture of the 3-4-5 chain housing cover? You would need a lot of patience to get this motor cleaned up. Keep us posted.

Tony

See pics below.

Planning to fix this airbox

Scatter is ok until it sits there for 6 months. That’s when I get into trouble.

Hi Tony. Of course I did smoke test 3 times with a smoke generator I bought just for this purpose. This crack is underneath the runners and either had a very small amount of smoke or I missed it which is as likely. When I pull my oil cap the rpm drops 50-75 as it should so not sure this is a big air leak. But of course I will fix it. What do you recommend JB Weld or something else?

Here are the pics you requested


http://forums.pelicanparts.com/uploa...1611508441.jpg
http://forums.pelicanparts.com/uploa...1611508441.jpg

Thanks for any replies!

PS Tony

You are right about patience needed. Good thing I am retired have plenty of time.
I will clean the engine as best I can to improve its appearance but not going to go crazy making it look new. I have a long list of items to check and/or repair and if I can clean up along the way so much the better. This will never be a show car.

Pressure washer supposed to be here tomorrow. We will see how it looks afterwards and go from there.

Cleaned the air box today.
Put in flashlight in one of the intake ports opposite the seam crack.

http://forums.pelicanparts.com/uploa...1611532304.jpg

The crack is under the two lower openings in this picture. No light shows through.

The injector sleeves were a real mess. I believe a lot more air coming through each of them. I have new sleeve O rings.

All pressure washed. Not as clean as I would like but as clean as I can get with a sprayer. An improvement for sure though.

http://forums.pelicanparts.com/uploa...1611687118.jpg
http://forums.pelicanparts.com/uploa...1611687118.jpg

http://forums.pelicanparts.com/uploa...1611687179.jpg

Found this on the ground after I cleaned up. Anyone recognize it? The washer may have just blown it out of a crevice on the motor somewhere. Looks like something from around the clutch arm.

http://forums.pelicanparts.com/uploa...1611687469.jpg

Note the capped off oil line above the tensioner opening. I assume these are original tensioners not the upgraded Carrera version.

If that is so I will replace the oil line with the correct original version and order two tensioner rebuild kits and tensioner guard kit from PP. The Carrera tensioner kits are outside my budget unfortunately. Maybe next time.

Does this sound like a good plan?

Thanks

If they aren't in your budget, buy them with a credit card. If those mechanical ones fail, which they can, your engine is donezo and you're going to need to pull it all the way apart. Unfamiliar with tensioner guard... if that can prevent failure maybe that is a more cost effective way.

Good idea with new lines, they aren't too much $.

the pin you found is from your rear decklid shock absorber(hood shock)..not to worry ...
Ivan

Oil fed tensioner kit $1000. Tensioner guards are $10 per side. PP sells both.

Thanks Ivan

that's a securing pin for either hood/lid shocks or the door band to A-pillar

rinse with brake cleaner quick, then go next level with baken oven cleaner and a brush to rub in a bit.
though follow application rules.
don't let it soak too long on bare cast Aluminium (20-30 minutues should do the job anyway).

Did some looking around last night. The Porsche priced tensioner kit that I had seen originally is $1200 per side, so $2400 total. The Sebro kit on PP is about $900 total for both sides which is at least sort of reasonable in the Porsche world.

Any issues with the Sebro kit?

Thanks