Another Engine Rebuild Thread - 80 3.0L
 

Well, my "spare" engine was delivered this week. I was so excited that I took off of work today in order to get started.

I bought an engine out of a 80 SC that needs to be rebuilt. I did this so that I could take my time with the rebuild while still enjoying my 82 SC. Once I am done I will swap the rebuilt engine into my 82 and use the CIS from my 82.

Right now I don't have an engine stand - hence the engine sitting on a pallet.

This is my first rebuild - I am a complete novice so I hope that this turns out well and inpires others to do the same when their engines are in need of a rebuild.

Below are pics from today's progress. I am at a stopping point until I get a stand - can't take off exhaust without it.

http://forums.pelicanparts.com/uploa...1206140069.jpg

http://forums.pelicanparts.com/uploa...1206140167.jpg

http://forums.pelicanparts.com/uploa...1206140201.jpg

http://forums.pelicanparts.com/uploa...1206140245.jpg

http://forums.pelicanparts.com/uploa...1206140282.jpg

http://forums.pelicanparts.com/uploa...1206140306.jpg

Some more quick pics.

http://forums.pelicanparts.com/uploa...1206140974.jpg

http://forums.pelicanparts.com/uploa...1206140987.jpg

http://forums.pelicanparts.com/uploa...1206141000.jpg

Subscribed. Will be interested to hear how it goes.

Subscribing for information.

Good luck with your project. I'll be interested to know if there are any issues with fitting a 82 CIS on a 80 engine.

Me too!

The 80 engine was supposed to have an external Voltage Regulator. When I pulled the alternator out yesterday it had the internal Volatage Regulator.

Is it common for people to switch from external VR to internal VR?

I managed to get the cat and muffler off even though the engine is still on the floor.

This allowed me to remove the lower valve cover gaskets and the chain covers.

The great news is that I found no broken or pulled head studs!

Keep in mind that I have limited info on this motor other than the fact that cylinder #3 has zero compression with 100% leakage and the other five have 140-160 compression and poor leakdown numbers (don't have specific numbers though).

Also, I took a closer look at the alternator today. I think it is pretty new based on the exterior condition. It looks like it was just put in. The fan housing has many cracks and the fan has a handful of chips.

Here are more pics from today.

Did I mention that this is the most fun I have had in a long long time? I restored an old house a few years ago and the demolition is always fun - same applies here. I am sure the good times will come to an end once I have to start cleaning and shelling out duckets.

http://forums.pelicanparts.com/uploa...1206220439.jpg

http://forums.pelicanparts.com/uploa...1206220459.jpg

Nice can't wait to see the progress. Those manuals look soooo clean right now!

Subscribed - What did you pay for the engine? - If you don't mind. Do you know how recently the engine was run?

The oil cooler is easy pickings while on the pallet - if you have a long enough extension. But get it up higher and save your back - keep having fun.

I think the internal voltage regulator is a good thing!

Looks like some yellow overspray from a car being painted? And, even maybe some primer, but what is that on the cylinder cover plates? Rust or dirt?

Wow! You have gotten down to the meat fast and should have answers to the question about cylinder three (3) soon as to the leakdown numbers being bad there. I'm betting/hoping it just needs a re-ring or maybe valve guides.

Also, it appears you are in the same boat I am with the 1978 3.0L having to use the crowfoot to remove cams, right?

Forgot to mention earlier that I think you have the Carrera pressure-fed tensioners in there already by the looks of it. If so, that is excellent and shows someone really cared about the engine's life-span.
SmileWavy

I paid $2k for it - shipping from Oklahoma to South Carolina was an additional $230 via Old Dominion Freight. ODF was absolutely great to deal with. They met me at my house and took the engine right into my garage.

Don't know how recently the engine was run but I am pretty positive it was within the last 6 months.

Yes, the car was yellow and there is a heck of a lot of overspray. Fortunately most of that will be gone when I drop my CIS on top and clean up that engine.

There is no rust (I thought same thing when it was coming off of the truck). It is red clay and grease!

It does have the updated tensioners but I may use the ones off of my current engine b/c they are only 10k miles old.

Subscribed!
Looking forward to rebuilding my 80 3.0 in a couple years, but this makes me want to drop it and tear it apart right now!

Ha! That is how I felt too when I saw others doing it.

It will be pretty cool to be able to say that you rebuilt a Porsche engine during your lifetime. That might seem sort of materialistic in terms of one's lifetime goals - but it is cool nonetheless!

I have an 80SC as well, I found a few broken head studs this past summer, so I'm going to be dropping and rebuilding once the weather becomes nicer around my parts. Man, it's been a long winter! I already purchased the engine stand and Yoke.. I've already decided to buy Race Ware head studs and I'll probably get a set of JE pistons. Hopefully my Cylinders are ok! I'll be posting pictures as well once i get started, keep your pic's coming, it's great to see them! SmileWavy

UPDATE:

Got engine stand this week. I managed to get some work buddies to lift the engine onto the stand on Friday - bought everyone lunch for helping. It was a little hairy at first b/c one of the buddies was a girl.

I made a lot of progress today. Pics will follow next week as I don't have my camera connection cord here at home.

SOOO ... a couple of interesting items to mention.

1) I have Mahle cylinders!
2) The cylinders were already scribed with numbers. :confused:

The scribed numbers on the cylinders were not visible until I pulled each cylinder. I only did 1-3 today (stuck on right side trying to get cam woodruf key out!).

Does this mean that the engine has been opened up before?

Hi MCA,

Do you have the engine on the stand yet? Let me know if you need a hand. I'm not that far away.

Yep, got it on stand yesterday and continued the tear down.

Thanks for offering to lend a hand. I really think that I will need help during assembly. Also, I have to drop the engine out of my 82 and insert the rebuilt engine ... that would be a great time to stop by!

Alright Flash Man you are doing exactly what I have in mind. Buying a engine in need of rebuild before I need to do my own. You mentioned OK. Did you purchase from OK foreign or an individual?
Keeps those pics coming :D

It came from Piedmont, OK. I bought it on eBay from 911-carrera2. He has an eBay store called Performance Motorsports Oklahoma.

http://cgi.ebay.com/ebaymotors/PORSCHE-911-3-0-ENGINE-COMPLETE_W0QQcmdZViewItemQQcategoryZ33615QQihZ016Q QitemZ260215252731QQrdZ1QQsspagenameZWDVW

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?