Cylinder 3, as seen from the intake manifold, and removing the valve cover.
Video of walk-around and intake manifold views: https://youtu.be/7dkaYhSgfvw

http://forums.pelicanparts.com/uploa...1751371354.jpg
http://forums.pelicanparts.com/uploa...1751371354.jpg
http://forums.pelicanparts.com/uploa...1751371354.jpg
http://forums.pelicanparts.com/uploa...1751371354.jpg
http://forums.pelicanparts.com/uploa...1751371354.jpg
http://forums.pelicanparts.com/uploa...1751371354.jpg

Now I'm waiting a few more days for my engine yoke to arrive so I can put it on the stand. In the meanwhile I have some CV joints to repack and plenty of cleaning to do on the CIS and other removed components.

I'd appreciate any thoughts on what level of rebuild we're looking at here. Also, any tips on cleaning what's come off already!

You probably should start with the thinking that pieces of metal have circulated around your engine in the oil as a result of the failure. This means a full strip and clean to be sure of removal. Sorry!

Yeah, we're going to take her to bits I think!

I'm hoping the oil flooding seen in some of the non-smashed cylinders isn't indicative of a larger issue.

On the positive side, I'm quite proud of how cleanly I lifted off the CIS.
After removing the throttle anchor plate and the EGR, it all lifted off together. Helps that I have worked on it extensively in the past.

http://forums.pelicanparts.com/uploa...1751396457.jpg
http://forums.pelicanparts.com/uploa...1751396457.jpg
http://forums.pelicanparts.com/uploa...1751396457.jpg

Yoke arrived, but won't fit on without removing some of the exhaust components. And those have been on for 25 years.

So... this morning I'm picking up a giant shallow tub (for drips) and a nut-buster to get this exhaust off. Hopefully she's mounted on the stand by this evening.

That is why the factory yoke is worth its weight in gold. I bought it 30 years ago and still use it.

It looks beautiful and is a huge beast. I'll feel a lot better with my expensive engine on it, than on the "universal" system of sliding brackets that comes with the stand.

Now just to get these evil exhaust bolts out. Ran all over town this morning and the only nut buster I could find is too large. Ordered some smaller ones, but won't be in until tomorrow.

Going to be a pain getting those bolts off without flipping the engine.

Yep, they have been very difficult. Still have 2 left of the 3.

http://forums.pelicanparts.com/uploa...1751557299.jpg
http://forums.pelicanparts.com/uploa...1751557299.jpg

Good progress so far. SmileWavy
However; Like others here I am sure, I'm still waiting for an explanation of why this might have happened, i.e.; missed gear, down shifting at too high an RPM ??? :confused:
Ant.

I was flooring it out of a light, as I usually do, and just about to shift to second. Didn't hit rev limiter, although revs were very high.

I got the bolts off that exhaust section. Combination of PB Blaster, nut buster, and hacksaw. There's still a pipe to the EGR which is needs to be loosened before I can get it free. That is proving to be stuck as well.

I had to destroy my heat exchangers with a sawz-all to move on with my project and not compromise exhaust studs. Carry on


Bill

That's horrifying! I think with blaster and some time I'll be able to get this last connection up to the EGR out of the way, and get it mounted on the stand.

There's an olde tool called a nut-splitter. It was made for rusted and eroded nuts on exhaust systems. You might try that.

I did get the nut splitter, although I'm going to need something else for this connector to the EGR tube.

But I was able to remove the cat and squeeze the yoke past the exhaust pipe. Now I just need to get some spacers and bolt it on, probably this evening.

Then I'll try using my motorcycle jack and build a platform with bricks and such to work the engine up high enough to mount on the stand.

For spacers, I used plumbing pipe nipples; they come in many lengths and seemed to be strong enough.

:)

She's on the stand! I used a metal spacer I found in my parts bin, along with 2 large nuts stolen from the stock engine stand. Getting it onto the stand was a real bear. I ended up using some ramps to make a high "shelf" and set the engine on it with the motorcycle lift. Then I put the lift higher up and stacked some blocks and lifted the engine again higher, this time with a stilt to the stand's angle.

She's on the stand! I used a metal spacer I found in my parts bin, along with 2 large nuts stolen from the stock engine stand. Getting it onto the stand was a real bear. I ended up using some ramps to make a high "shelf" and set the engine on it with the motorcycle lift. Then I put the lift higher up and stacked some blocks and lifted the engine again higher, this time with a stilt to the stand's angle.

http://forums.pelicanparts.com/uploa...1751636176.jpg

Then she went right on (and started dripping some more).

http://forums.pelicanparts.com/uploa...1751636219.jpg

Now to start pulling off the exhaust. Found some interesting things.

The joint between the heat exchanger and the crossing exhaust pipe on the 4-5-6 side was full of oil. Probably half a cup came out when I opened that part up. Note that my destroyed valve was 3.

Taking off the heat exchangers wasn't as tricky as I feared. The inner bolts on the exchangers were actually just stacked with washers, maybe as a stand-off? Not sure how that worked. But that meant I just had the 8mm studs and then 3 nuts per side.

4-5-6 side was pretty oily, especially at 6.

http://forums.pelicanparts.com/uploa...1751636537.jpg

1-2-3 was not as oily. Here's a video of her as she stands now. (May take a minute to be available).

https://youtu.be/6zh79LVmjPE

Video of the from the top. Three is the boomed cylinder.

<iframe width="560" height="315" src="https://www.youtube.com/embed/D9G9zfOnCsM" frameborder="0" allowfullscreen></iframe>

Video from the bottom.

<iframe width="560" height="315" src="https://www.youtube.com/embed/HEfylfChkLI" frameborder="0" allowfullscreen></iframe>

Obviously I want to know why this happened.
Is there anything I should note, record, or measure as I take things apart to help me identify the cause? I'm trying to take a lot of photos and some good videos, but I don't know what to look for besides "the broken parts" and "lots of oil/dirt" where it shouldn't be.

Take pictures as you disassemble it. The valve guide is gone, so I would want to know where that went.

:)

Good work, Opening the chain box covers should be enlightening. I noticed in the video the sump cover is on, did you take it off to drain the oil and then put it back on ?

I did not take it off yet. Should I do that now?

Cam housing covers are now off. I need to identify the correct Porsche Tool(s) to remove my camshafts. I took some careful pictures, so that should help me identify the right ones.

Then while I'm waiting for the special tool, I can clean things up.

http://forums.pelicanparts.com/uploa...1751724891.jpg
http://forums.pelicanparts.com/uploa...1751724891.jpg
http://forums.pelicanparts.com/uploa...1751724891.jpg

Start by Tearing it down to the case, pull all the oil plugs and piston squirters. This thread should be over in the engine forum.

Aha, engine forum! I didn't even think of the fact that there's a rebuild-focused subforum. Here's a new thread - I'll make future updates over there.

Engine Rebuild Subforum Thread

hi Rod
i know this is off topic, but how loud is that exhaust setup your're running?

Hi Mike. Pretty loud WOT. Burbles a bit at idle. I can drive it under the noise radar, but when I’m on it you notice me. Lots of compliments at the track on how nice it sounds especially when bouncing off a wall.

Big surprise in the engine teardown thread - the camshaft bolt was loose! Going to see where this leads...

https://forums.pelicanparts.com/911-engine-rebuilding-forum/1179839-1979-sc-chewed-valve-total-rebuild-2.html#post12493691

I think I may have located the instigating failure. The rocker shaft on the valve rocker that failed was far far out of alignment.
https://forums.pelicanparts.com/911-engine-rebuilding-forum/1179839-1979-sc-chewed-valve-total-rebuild-3.html#post12494493

Thanks for that.
I must be getting old... looking for something quieter these days :)