UPDATE:

Today I was able to remove the right chain housing, heads/camshafts, cylinders and pistons. I did the left side yesterday.

I promise that I will have a lot of pics coming this week once I get my camera cord.

HERE IS THE INTERESTING PART.

1) All cylinders were already scribed 1-6
2) All pistons were already scribed 1-6
3) ALL OF MY HEADSTUDS ARE STEEL (none pulled / no timeserts)

If I had Dilvar, the magnet would not attract right?

The above items suggest that it has been rebuilt at some time in the past right?

Currently I have just the core on the stand. I can't continue b/c the flywheel 12 star tool is too long - wrench won't fit in between the flywheel bolts and the engine stand. Need to find a shorter tool.

PICS BELOW ------------------

Left Side: Preparing to remove cams/heads
http://forums.pelicanparts.com/uploa...1208219254.jpg


Left Side: Preparing to remove cylinders. Cams/heads pulled.
http://forums.pelicanparts.com/uploa...1208219335.jpg

Left Side: Cylinders pulled. Can see pistons 1-3.
http://forums.pelicanparts.com/uploa...1208219415.jpg

Here Is #3 - 100% Leakdown And Zero Compression
 

Pics of piston #3 - 100% Leakdown And Zero Compression
http://forums.pelicanparts.com/uploa...1208219516.jpg

http://forums.pelicanparts.com/uploa...1208219529.jpg

http://forums.pelicanparts.com/uploa...1208219542.jpg

Pic of head #3
http://forums.pelicanparts.com/uploa...1208219577.jpg

Pics of block
http://forums.pelicanparts.com/uploa...1208219624.jpg

http://forums.pelicanparts.com/uploa...1208219639.jpg

Looking good! Let me know if I can be any help. I dropped mine last week to get ready for a new clutch and some ' while it's out of the car stuff ' .

Hey Chris!

I appreciate the offer! I am going to be splitting the case this weekend if you want to stop by. I want to get some more eyes on this thing so I can determine what will be needed for the rebuild.

If you need any assistance on your end, please let me know. I don't mind taking a break from mine every now and then - gets a little emotionally draining for me. In fact, I crashed hard on Monday and left work around 10am ... slept all day. Not sure if I had bug, too many brake cleaner fumes, or something else, but I was exhausted.

Here's a teaser of what you can get to at the end of the tunnel..

http://forums.pelicanparts.com/uploa...1208392074.jpg

I used Eastwood clear on all the aluminum (not the block, cyls and heads) and Eastwood Detail Gray on the bead blasted (inside and out) intake runners. Injectors should be flow tested or replaced, not a big cost.


http://forums.pelicanparts.com/uploa...1208392238.jpg

Try (in a well ventilated area) rubbing alcohol for cleaning instead of brake cleaner. It is a pretty good solvent, and it says on the label that you can soak your hands and feet in it... Try that with brake cleaner! You may have to coat with a light oil so steel parts don't rust after degreasing.
Watch out for open flame and don't drink it!!! 1 gallon or 4L containers are available...

Gary -
Nice work man! Looks fantastic! Thanks for sharing.

Bill -
I appreciate the tips on using Alcohol. The brake cleaner is pretty potent stuff. As you can see, the engine I bought is quite nasty ... gonna take lots of work.

subscribed...

Gary>> wish I had taken your COA [course of action].. when my 3.0 needed re-build..... I just didn't have the cajones to do it myself....

Don't be giving me too much credit. I took the parts and bead blasted/refinished them but my race shop built the motor so I could compete in PCA and NASA this year. The build credit goes to Dan Jacobs LLC, I just made it pretty.. :D



Those shocks (Bilsteins) are John Deere green, the trailing arms are Eastwood Argent Silver.. all glass beaded 1st. The shroud is, of course, Porsche Speed Yellow from PPG Concept single stage.. :phttp://forums.pelicanparts.com/uploa...1208399265.jpg

We need to give that engine stand a screen name...

I can’t think of anything clever, so I'll nominate something appropriate:

Much Appreciated. :)

Ha! Absolutely ... need to think about that one.

Thanks again Kevin for letting me borrow it. You are really helping me keep my budget within reason. :)

Pics from today's progress. Split case and then moved to the camshaft / heads for #s 1,2,3. I will do 4,5,6 tomorrow.

I can only seem to work for a few hours at a time before I wear out. Then I usually cut the grass or something and come back for a few more hours.

So far, the most difficult (time consuming) thing to do was remove the exhaust and the rocker arms. Everything else has been quite easy.

Oh... #3 cylinder head was really tough to remove. This is cylinder that had zero compression and 100% leakdown. Not sure where it was binding but it was quite a challenge to get it off compared to #1 and #2.

http://forums.pelicanparts.com/uploa...1208653860.jpg

http://forums.pelicanparts.com/uploa...1208653877.jpg

http://forums.pelicanparts.com/uploa...1208654054.jpg

http://forums.pelicanparts.com/uploa...1208653972.jpg

http://forums.pelicanparts.com/uploa...1208654003.jpg

subscribed...

+1 Great thread. I'm in.

Looks like fun!

Couldn't see from the pics.... Any clue as to what was causing your compression loss on #3? Subscribed....

I suggest you save yourself a time cleaning by finding a shop with a large parts washer.
Case, cam towers, heads, nuts, bolts, etc go in there and come out pretty clean.

Cannot see why #3 had 0 compression.
Mahle P/C's are probably reusable; a shop can spec them.

If you use new chains, replace the chain sprockets on the I-shaft with new ones:

http://forums.pelicanparts.com/porsche-911-technical-forum/200267-new-chains-without-new-sprockets-read.html

It is official ... tear down is complete!
 

Finished up the tear down today. Removed 4,5, and 6 rockers and heads. Then removed rods from crankshaft. Only one of the rod bearings looked bad (although all will be replaced anyhow). You can see the grooves in the pic below.

Now I need to get some help with inspecting everything so that I can construct a plan and place my huge order with Pelican.

I decided to go ahead with the modest upgrades - JE Pistons (95mm), 964 Cams. I think that is really all I can do with CIS without a huge bump in displacement.

Bad rod bearing:
http://forums.pelicanparts.com/uploa...1208721311.jpg

The others looks like this:
http://forums.pelicanparts.com/uploa...1208721325.jpg

Crankshaft close-ups:
http://forums.pelicanparts.com/uploa...1208721336.jpg

http://forums.pelicanparts.com/uploa...1208721347.jpg

http://forums.pelicanparts.com/uploa...1208721364.jpg

http://forums.pelicanparts.com/uploa...1208721376.jpg


Keep in mind that this is the first time that I have ever seen the inside of an engine - really the first time I have ever seen an engine out of a car. :eek:

If anyone detects something odd in any of the photos, please speak up.

Should I grab more pics of #3 piston and cylinder?