Ultimate 3.6 conversion 993tt

[jevvy]

After doing a 3.6 into an 89 911 and a Vram into a 964 I really wanted to try a tt transplant. I'd been hunting for an engine for years and one came up fairly local to me - be rude not to:



Engine came from a car that had been in a bit of a shunt - I saw the car and the documents (60k miles FSH) so decided to bite the bullet and get it bought. I got the loom, ECU, intercooler and gearbox, this is the car its going into:

[jevvy]

I'm going to resist a full rebuild until after I have fitted it but have been spending some time tearing it down so I can check everything and do all the seals etc, below is a selection of pics from this process:

As collected


Removing flywheel to fit engine stand mount


Unfortunately the mount wouldnt fit with the alloy charge tubes so plan B was needed


Looks like it should fit - limited space though.


New home for a few months

[jevvy]

Removed SAI system


Removing the alternator and fan



Heat pipe removal


Then the AC/oil pump bracket


Oil pump drive



Oil pump - how cool is that!


Removing intake & power steering pump removed


Intake removed


Kinda clean

[jevvy]

First heat exchanger off, put up a fair fight


993 TT heat exchanger compared to a 993 NA heat exchanger:


993 TT gearbox, need to remove the viscous coupling and sort a different nose cover. I think I also need to update the mount slightly to run in 2WD mode which I need to look into a bit more:


Second heat exchanger off, put up much more of a fight than HE #1.


Looks almost like a normal 3.6 now:


Clean up/check of the intake:


Half way there:

[jevvy]

Never realised the bottom crossover chamber on a TT engine is blanked off and effectively an empty chamber where the resonance flap would be on an NA motor - whats all that about?


Quick clean up of the HE's:


Found some rebuilt standard turbos:




Bit more time today to have a play and a think...

Tried the intercooler in the track IB which has a ducktail:



Seems to fit just fine without the big tray that is fitted to it in a 993.

A snap from the side makes it look like it will fit with the duck if I hack a few chunks out of it (the duck not the IC):





So with a bit of work I think the duck is a go-er. Here the IC is roughly placed in the spare duck I have:



Think its a case of fit the engine, mark where the duck needs a trim then try to make up a nice seal of some sort to make sure as much air as possible is getting drawn in through the IC.

[jevvy]

So I was checking the intake gasket thingys the other day and spotted some debris:



Hmm - that cant be good so decided to pull the cover:




Hope I can remember where all this goes:






All went well apart from these little tinkers:

[jevvy]

Bit more tinkering over the past week or so, firstly some bad news: Check this little tinker out





From the state of the break area it looks like it happened a while ago. Its non load bearing so I think I'll try a macGyver repair first to save yanking the chain box - any other ideas?

Another lucky find:


I think I'll send them off for a refurb or maybe just track down some new ones.

Parts stock is gathering pace, amazing how expensive all the little seals and stuff are but would be silly to not do them while I'm at this stage


Ready for the next phase:


Sorry for the blurry pic but does anyone know if the fingers on the stainless air diverter jobby are supposed to line up with the gaps or the fins - I seem to have a mixture of both?


Valve cover off:

[jevvy]

Cams look clean:


Cleaned up ready for new gaskets on the valve cover:


New(Bosch) vs old(Beru) plugs - slight variation in part number (FR6LDC vs FR6LDU)


Bottom valve cover off:


Chain box cover removed ready for new gasket and o rings:


Chain box looking fairly clean:


I was tempted to tear into it further but after a chat with Ray @ Northways and the fact my labour is free I'm gona just do all the perishable seals and chuck it in and see what its like.

[group911@aol.co]

The cam seals and chain box to case seals are a normal source of leaks.

[Competizione]

Fantastic project... Looking forward to following progress. Best of luck.

[jpnovak]

This is going to be an incredible build. Something I have had in my head for a while. I had planned something similar until the price of 964s made them out of budget.

Is your 89 a C4?

[sand_man]

Subscribe....

[jevvy]

Originally Posted by group911@aol.co

The cam seals and chain box to case seals are a normal source of leaks.

Thanks Bob, Chain box to case and cam seals are very dry so I'm not going to poke that bear for now. I'm ditching the power steering drive and fitting an electric pump up in the front trunk so that will eliminate the leaks at the other end of one of the cams too.

Originally Posted by Competizione

Fantastic project... Looking forward to following progress. Best of luck.

Thanks, should be pretty mental. The ECU is the 430bhp version too which was a pleasant surprise when I picked the ECU up shortly after collecting the engine.

Originally Posted by jpnovak

This is going to be an incredible build. Something I have had in my head for a while. I had planned something similar until the price of 964s made them out of budget.

Is your 89 a C4?

Its a 90 C2, bought just before the prices went mental. With it being a C2 I need to fettle the nose of the tt gearbox and look at the mount. Also need to deal with the lack of speedo feed on the 993 box but that shouldn't be too hard I dont think.

[sand_man]

It has been a few years, but this was one of my all time favorite builds...EVAR! Complete perfection! Not sure if he (LARennsport) is still on the boards, but worth a shot if you run into any snags or have questions:

1-of-1 964R Turbo....

[sand_man]

I might have some additional pictures on an old computer. I will look...

And on Rennlist he is LA964RS:
http://rennlist.com/forums/964-forum/435168-finished-964tt-pics.html

[jpnovak]

Why not stick with the stock G50? It should handle that 450HP level with no problem. Plus, not fitment issues since you just bolt it up to the engine.

I do realize the gear ratios are different but that might not be a bad thing. Not really a lot of places in UK to really explore the top of 5th!

Just trying to make the project a little easier.

[jevvy]

Jeff - thanks for the links on the white car, if you have any more details/pics im all ears.

Jamie - if i get the engine done before i find a new nose for the tt gearbox i will probably do just as you suggest, should be fun with either gearbox

[al lkosmal]

I'm going to watch this one.................I haven't entered the turbo world yet, but .............I'm get more interested when I see a cool DIY project like this.
regards,
al