Help me remove Rajay turbo system from 2.7

[jpearson]

I wasn't sure where to put this thread - I am going to try the technical forum and see how it goes.

Some of you have helped me already with some basic questions and I am very thankful. I bought a basket case 75 911s about three months ago - basically as a project. My goals are to return it to largely original condition as a nice driver car. So far I have restored the gas tank, rebuilt the pedal cluster, and rebuilt all the calipers (plan to start a separate thread to chronicle all the projects). I drove the car a few days and now I am starting the next round.

I have very little mechanical experience and no engine experience so this is all very new to me. My car came equipped with a Rajay Turbo system. I order to prolong the life of the 2.7 engine and just keep the car original I want to remove the system. I started digging in today. Here are some pics:




I removed the turbo unit today but the difficult thing for me will be the details of how it was connected to the engine. The oil for the unit came from the chain housing cover. I don't think this is a stock housing cover. One question I have is will I need to replace this?



The next complicated part is the wiring. Here is a picture of the turbo control box. Wires go from this to the gauge in the car and to the blue cyclinder (not sure what it is) attached to the fan housing. I am going to start working on this tomorrow. Is anything supposed to go where the red turbo control box is? Any general advice about this part of the project?






The last difficult part is where the air entered the fuel injection system. I am not even prepared to ask questions about that yet.



I truly appreciate any help, answers to my questions, and general advice. A little abuse is even welcome.

[jpearson]

One other thing: Once I get this system removed and the car running again I will probably try to sell it. Any thoughts on the value for the entire system? Anyone interested?

[Flieger]

Blue cylinder is the ignition coil. The "Turbo Timing Master" box may be an early turbo timer that keeps the car running for a while after you shut off the engine so that it can cool off the turbo. You don't need an automatic system to do that, just wait before shutting it down to cool the turbo so the oil does not coke.

[ant7]

hi,
well i will give you my two pence worth.
If it was my car, i would remove everything that was related to the Turbo system, then start re-assembling the original set up from scratch,There are some very good exploded views of the engine compartment on here somewhere, so you can work a lot out from there, one issue you may have is the distributor, this may have been altered or changed for one with diffrent advance curves, you need to find that out before you start running the car as standard.
Hope this helps, there will be plenty of very knowledgable people here who i am sure can help further.
Good luck with it.
Anthony.

[crustychief]

Good choice in removing the turbo, You will learn a lot about your car rather quickly.
? Wow, it looks like a hardware store exploded in the engine compartment.

[GaryR]

If your lucky you can find a complete CIS intake and just trash that hacked up mess. What were the leakdown and compression numbers, assume you knew the engine was healthy as a starting point?

[Targalid]

Usually turbo cars have lower compression pistons installed. Check the compression for clues about this. One of the other experts may have a simple way to tell what compression ratio you have.

[al lkosmal]

the chain housing cover appears to be stock, but modded with the oil plumbing fitting. You could remove the oil fitting and use a threaded plug here, but used, good chain housing covers are inexpensive.

As far as the electrical panel: You have the Voltage regulator (black regtangular unit) and what appears to be a rear window defrost relay (silver rectangular unit).....but i don't see the Bosch CDI (Capacitive Discharge ignition) unit or equivalent. Your Turbo timing Master controller is in its spot.

does that red controller have a manufacturers name on it? Is it a Rajay part...or perhaps an early MSD part?

The stock intake has been replaced. You are missing the throttle body and the boot that connects the throttle body to the air intake/meter.......and it's not clear if the air metering flap that is connected to the fuel distributor (black unit with all the fuel lines running to and out of it) is still stock or modded.

PS: I have a stock throttle body, from a good running 2.7, if you're interested.........probably a few other 2.7 parts in my stash. I may be interested in your rajay unit.....so some trading could occur.

[copbait73]

From my perspective you are getting a lot for distorted advice and bias, purest be damned.

The turbo kit is a "bolt on" The CIS was not hacked, you will need the stock rubber boot from the intake to the throttle body, a muffler, a plug for the oil outlet drain to cover and a cap for the oil inlet line.

Be prepared for the results of your efforts, a old 2.7L motor with noticeably less HP and torque.

This is not a desirable engine stock or otherwise so why take it back to it's anemic origins?

[jpearson]

Thanks for the input. Hopefully I'll get some time this afternoon to get back at it. I haven't done any engine testing yet. It runs well but there are some sig. Oil leaks so I know a rebuild may be needed. I am already bouncing back and forth between Wayne's engine book and a textbook on engine fundamentals. A little moreinfo about the wiring - the control box is actually wired to the boost control knob and the distributor. How do I tell if I need a different distributor?

[Targalid]

One other comment. Stock 75 cars are more desirable in California because they are exempt from certain smog regulations. It may have more value there than a 76 or 77 car with the 2.7 engine just because it is a 75 and therefore easier to own.

[GaryR]

Originally Posted by copbait73

The turbo kit is a "bolt on" The CIS was not hacked

Was referring to the whole mess, not just the CIS. Looking at the oil line, fittings, the cut airbox cover, the wiring, the welded/re-welded turbo Y pipe, what appears to be a weld on the turbo casting itself, have to stand behind what I see and respectfully disagree.

[Scott R]

Originally Posted by GaryR

Was referring to the whole mess, not just the CIS. Looking at the oil line, fittings, the cut airbox cover, the wiring, the welded/re-welded turbo Y pipe, what appears to be a weld on the turbo casting itself, have to stand behind what I see and respectfully disagree.

I would second this option. Take it all out, get a complete CIS system and a wiring harness for it.

[RatBox]

I'm curious what model Rayjay Bob (BAE) used on the 911 set-ups. Can you post the numbers on the ID plate.

thx

[304065]

Drop the engine. It's a lot easier to figure it out with the engine on the stand.

[Ronnie's.930]

Hard to believe you want to neuter the car . . .

[Dr J]

A turbocharge kit is hard to come by. It will sell easily. However, I suggest you drive another 2.7 without a turbo before you do that. On the other hand, you could use the money if you are intent in trying to restore it. The 1975 model is not the best year to invest money in.

[jpearson]

Thanks for all the great input so far. I'll begin by saying that although I appreciate everyone's feedback, I am not changing my plans for the car. I realize that the car has little to no investment potential but I am determined to do all the work myself. If I destroy the car at least it wasn't some highly collectible carrera. Performance is also not an issue, I'm not looking to race and in fact I hardly ever speed. Most of what this car will see is town driving and some Sunday drives on curvy mountain roads. I want an original classic porsche that I know I built (for better or worse) that I plan to enjoy long term.

Now on to the project:
This afternoon I removed the Boost Guard from under the car along with the boost control and gauge from inside the car. Because some of the hoses attach to the back of the CIS, I decided to remove the entire unit to figure it out. It is almost ready to remove but there are a few electrical attachments in back I can't figure out how to get at yet. It may be that I need to drop the engine to finish it. If so there are a few other projects that I need to plan first. I'll post some pics when I get a chance (I also got some nice video of my 2.5 year old luging down the driveway on my crawler). A few issues were raised:

al lkosnal - Thanks for the info about the Bosch CDI. I haven't had a chance to do any reading yet, what is the purpose/function of the CDI?

Ratbox - the model of the turbo is 301E70.

Ant7 - How do I determine if the distributor has been altered?

The project is going to be paused for about two weeks because my parents are coming to see the grandkids and my dad and I are going to build a shed so I can clear some room out in my garage. It's funny how a car project can spin off in so many directions. My wife has already used the word obsessed more than once.

[Porchcar guy]

I'm confused, in post #2 you said you would probably sell it and one day later, you said you wanted to enjoy it long term...Which is it ? Not to be a naysayer but I hope you realize what you are trying to attempt. Your question about the blue cylinder...COIL... shows a lack of knowledge about engines...Anyone into cars for any length of time , knows what a coil is, the shape and function. CDI is a capacitive discharge ignition control box...Good Luck...this project is not for the feint of heart !!

[911pcars]

I don't know the condition of the engine, but unless it's been built to withstand the boost pressure generated by this turbo, it will probably need a rebuild. If the condition of the car is borderline, I'd suspect the engine is close to that level as well. Owners with new-found power tend use it more often, and turbos are not kind to engines without proper preparation.

Perform a compression test and let us know what the results are.

Sherwood