Another Engine Rebuild Thread - 80 3.0L

[mca]

Originally Posted by 911 tweaks

I think a little confusion here Craig, possibly ??

To begin with, the metal intake runner (there are 6 of these... the bent pipes if you will) and these each have a orangie/red plastic sleeve that is staked into the intake runner by the triangular shaped "stake" indentation right above the top lip of the sleeve. These are cheap @ ~$6.00 ea. IF any of these are loose or have popped out it is best to at minimum to install new ones. Really best to do them all as once you do 1 they are easy.

As for the metal pencil shaped actual fuel injector, those pull out not to tough even if in the car. Make sure to use new rubber o-rings when install.

So, which are you contemplating and/or having questions about since I just rambled off here...?
Bob

I see now ... I was under the impression that you could "punch" the inside of the intake runner ... hence, staking it in.

[mca]

I took the day off and am nearly ready for the install. I have pics but I will post them later.

Unfortunately I had a major set back tonight. I had to say goodbye to Buster, my 16 year old Jack Russell Terrier. He passed at around 8:30 p.m.

Buster was with me 24 hours a day every day - right next to me at work, right next to me in bed, licking his paws while I was in the shower. I will miss him terribly.

Hopefully I can pull myself together for tomorrow. If not, Kevin and I will get some stuff done and then wait until a better time.

[wastintime]

I'm going to be succinct becuase after having parents, relatives, friends, and pets die; I've found that there is no right thing to say and almost nothing comes out right, but... man i'm sorry dude.

Andy

[dentist90]

Yup, it hurts. They are part of the family.

[mca]

Thanks guys. Yes, today was quite tough. Kevin came over and put me to work - he got me laughing a bunch too which was nice.

We got to the point of getting the engine and tranny back in and then stopped. I was a long day and I needed some rest. Hopefully I can complete all of the connections and fire her up tomorrow.

Today we (Kevin for the most part) installed the clutch, replaced two tranny seals, installed the exhaust, got the engine off of the stand and completely mounted into the car ... a pretty good day.

Here are some pics.

[911 tweaks]

sorry for the loss Craig... hard to say the right thing when this happens, but, time does heal all...

Great to see that you got out and got a lot accomplished on the car... that will help keep your mind off of stuff and surly pass the time...

Take care !!
Bob

[billybek]

Sorry to hear of your dog....
It is amazing that we buy into the fact they will be with us for 10-15 years and every time we lose one it impacts our lives so much....
It is amazingly hard....
It is good on the other hand to see you making progress... Post some start up video for us, will you?
Best!

[wilke3169]

Craig, I am sorry about Buster. If I didnt say the right thing when you told me yesterday it was because I didnt know the right thing to say. I do hope the progress was good therapy. We are so close.
If anyone wants their transmission cleaned send it to Craig. The photos don't show what a fine job he did. I think with the cleaner and Craig's time it will be slightly less than the price of a GT-3.
Keep up the good work, Craig. Can't wait to see the smile on your face when it cranks the first time.

[mca]

Ok, I am trying to install this hard oil line - same one that is used when people back date.

I have seen pics of this before and I understand that the bracket on the oil line should be anchored to the engine tin near the oil cooler. Mine is WAY off.

When I tighten the line to the case the line kicks out towards the shock - away from the engine tin where it should be anchored.

Is my line messed up? Is it crooked?

There is no way for me to get it away from the shock b/c the fitting on the oil line forces it in that direction as the line fits into the case when tightened.

Please disregard the ghetto bracket.





Crooked? The line bends away from the angle of the case fitting.

[Charlie V]

just bend it into position. gently.

[wastintime]

Yeah, bending isn't bad... lol, you should see the times we've taken a block of wood and a hammer to an oil line becuase something was rubbing in a race... they're pretty stout.

[mca]

thanks fellas!

[Dixie]

You need to keep Kevin workin'. Not reading RiceRods like you show in your photo!

[mca]

WE HAVE LIFT OFF!

YES!

Kevin came over early this morning to help wrap up the final tid bits - add washers to pressure plate bolts (removed starter to gain access), intall hard oil line, install clutch components, install sway bar, and add oil.

After a couple of hours trying to start her up with no luck, I mentioned to Kevin that I may have installed the dizzy at the wrong end of TDC. We corrected that error and she fired right up.

We ran her for 20+ minutes then shut her down. The alternator was not working which I later discovered was caused by a missing woodruff key - the fan can't spin the alternator if the woodruff key knocked out of its place.

Besides the alternator issue, there may be an exhaust leak. Not sure exactly where it is coming from but I checked all of the nuts and everything was tight. Could have to do with the gaskets. Need to investigate.

I am happy to say that there were no fuel or oil leaks. Dry as a bone!

Tomorrow I will install the bumper and then take her for a drive.

[wastintime]

Sweet... why'd you take the bumper off, btw... just to clear the Bursch?

Awesome man, the first engine you build is always fun!

[TibetanT]

I think by the looks of it, Kevin was reading Wayne's book, 101 Projects for your Porsche 911...at least it looks like he is.

Great promotion for Wayne's website too, huh? Here, the thread is featuring lots of information, pictures and tips from the Pelican community as to how the engine work should transpire, and from Wayne's Engine rebuilding book, How to Rebuild and Modify Porsche Engines. And, all of the wonderful "experienced" engine builders are present to keep things moving in a very positive direction. Way cool!

Sorry about your dog, I know how you must feel. In my eighteen years of handling and living with them all, it doesn't make things easy when one passes. I still miss them all.

Great job on the engine! Have fun with the drive tomorrow. I'm keeping my fingers crossed for a good run.

[mca]

Originally Posted by wastintime

Sweet... why'd you take the bumper off, btw... just to clear the Bursch?

Awesome man, the first engine you build is always fun!

Thanks Andy.

We took the bumper off in order to get the engine out. Not enough clearance with the jack stands at their highest setting.

[mca]

Ok, I took the car for 2 driving sessions today. All is great except that the alternator light is STILL on and my exhaust sounds like crap.

Before I replace the alternator, I'd like to investigate other possibilities.

Here is the scoop:
The alternator light and OXS lights are on (and BRIGHT) until I hit roughly 2000 RPMs and then both dim out completely as the RPMs increase. Not sure why the OXS light is on again. I just reset it 3000 miles ago. Maybe it came on after hitting 130,000 k miles?

Anyhow, the 101 Projects book (p.62) does not include this scenario in its troubleshooting guidelines. The closest match is when the alternator light is dim to start and then goes out with RPM increase. Mine starts bright and goes out.

The voltage with the engine running is around 11 and with the engine off it is 12. I had to charge the battery overnight due to the alternator not working yesterday. It is a red top optima - about 6 months old.

Any ideas?

[Elombard]

did you get the regulator plugged in? OR is it internally regulated? I had weird issues with mine when I switched motors and did not realize the new motor needed an external regulator. The Alternator is NOT working at 11 right? should be 14.

[mca]

Has internal VR ... it is the same alternator that was in it before I pulled it out and it was working fine prior to putting in the rebuilt engine. I replaced the VR just over a year ago.

I took a look at the tranny ground and it seems fine.

I do have an alternator from the 80 engine but I can't get it to separate from the fan housing to save my life!!!!!

Very frustrating indeed.