Engine Drop 3.2 after 4 years thinking about it!

bodmin · 04-25-2013, 08:53 PM

As one of Pelican’s most prolific posters (4 posts in 4 years!) I finally achieved my ambition and dropped the engine of my 1989 3.2 Carrera. The posts on this board have been wonderful – all my questions answered with a quick search. I don’t have much to add to existing knowledge base, but thought I would post some pictures.

Carrera 3.2 Newbie Intro

The main reason for the engine drop on my ‘garage queen’ is to have the underside of the engine looking as good as the topside. I also intend to refurbish the rear suspension, and under wing areas including the oil tank. I will not be doing any intrusive work on the engine, but will be removing the heat exchangers, replacing exhaust studs, and installing stainless heat exchangers (not SSI).

Some observations/comments as follows:

1. Car is now wingless with addition of new genuine Porsche engine lid.

2. The combination of a hydraulic scissor lift and hydraulic table made it a pleasure to drop the engine.

3. The drive shaft cap screw were very stiff. Used an extended 8mm hex bit socket with 600mm ½” extension to allow torque to be applied from outside the wheel well. All removed successfully.

4. Broke one end of the engine support bar using an air wrench. The engine mount bolt appeared to be seized, so tried rocking it with the air wrench. This bent the end of the support bar which eventually snapped.

5. The clutch cross shaft was a completely seized. Tried using a slide hammer to no avail (the end thread in the cross shaft is 8mm, not 6mm as posted elsewhere). Then made up a puller consisting of screwed rod with a strongback and nut. Stripped the thread of the nut. Then used oxy/acetylene with my puller still attched. Heard a couple of pings when heating the bearing closest to the puller. After it moved 2mm used the slide hammer to remove it completely.

6. Squashed one of the reference sensors when trying to remove it from the housing – it was (and still is) well seized.

7. Bought a P201 engine yoke and engine stand. Not really necessary with non-intrusive engine work this time around, but I may get more adventurous sometime in future.

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bodmin · 04-25-2013, 09:07 PM

Now that I've got the hang of it here's some more pictures.

wildcat077 · wildcat077's Garage

Nice work !
your engine and gearbox seem pretty clean to begin with ... when i dropped mine last year it took me two weeks to clean the accumulated oil and grime on both !

Cheers !
Phil

MMiller · 04-26-2013, 04:36 AM

Beautiful car and great job! Looks like you have a nice work space as well..

regards,

CCM911 · 04-26-2013, 05:59 AM

Wow! Just wow! I was going to suggest a good claening of the underside, but judging by your wheel wells, it looks like you have a very clean car! Nothing you listed sounds like a huge deal. Good job. Just make sure you orient the clutch disc properly if you remove the pressure plate.

Congratulations on a great job!

JJ 911SC · JJ 911SC's Garage

Good for you, look great.

Now take it easy, you almost double your number of posts in no time

While its out and you are in there... Time for upgrade

bodmin · 05-28-2013, 08:40 PM

Time for a progress update.

Gearbox has been soda blasted.

Alternator coming off

Heat exchangers removed. I must be one of the chosen few who managed not to break any exhaust studs!

Topsides removed

Rear bumper removed

tazzieman · tazzieman's Garage

That car has had a pampered life!

bodmin · 05-28-2013, 09:22 PM

Oil tank removed. Four of the five nuts holding the level sensor loosened ok. The fifth one did not break free and I'm reluctant to increase the torque. It is undergoing a penetrating oil soak, and if that doesn't work it will be threatened with the oxy acetylene.

Fule pipes removed. These will be replaced with genuine Porsche items (including Porsche tax).

And in the middle of the Porsche project my builders arrived to refurbish and re-roof the garages I own next to my house in Edinburgh. Not a good idea for obvious reasons. The Porsche is well covered and all delicate parts stored away.

As another aside here is a picture of the Clubsport I bought new in 1988, and just found out recently that the second owner lives 1/2 mile from me in central Edinburgh, and still owns it! The picture was take in the yard of the local Porsche dealer - it is in for a brake repair. The present owner is a delighful character and we found out that our paths have crossed unwittingly several times going back 43 years! I'm hoping to be the 1st and 3rd owner of the Clubsport one day!

As another aside here is some bike porn. I cycled 81 miles in a charity race a couple of weeks ago - the last 20 miles nearly killed me - too much for my ageing physique. In the garage of my Pethshire house were two Pinarellos. two Cipollinis, and one Museeuw - one with Campagnolo EPS, and one with Shimano Di2 (electronic gearshift to the uninitiated). That's me in the bottom picture second from the left.

dan88911 · 05-28-2013, 09:26 PM

WOW! thanks for posting great photos, bodmin.
Plan to drop my engine in the future.

bodmin · 10-12-2013, 09:41 PM

I haven't posted for several months, so I thought it was about time for an update. Project Porsche was interrupted for various reasons - garage refurbishment (not a good idea in the middle of a project), built a workbench, bought a new Gyrocopter, school holidays, major household projects (both houses), etc, etc.

On the odd occasions when I get to work on the car I have managed to strip the rear suspension, removed oil lines, and taken apart various other bits. The undercarriage was never as clean as the rest of the car, but I think I now have everything apart that I intend to take apart. From now on it's cleaning, blasting, painting / plating, and reassembly.

I may do some engine work, although this was not my original intention. However I have bought various tools from Pelican which were hand carried across the world by one of my American colleagues. (Camshaft holding bar, front & rear oil seal installation tools, Stromski hold down bolts, etc). Extravagant I know, but I am renowned for buying tools I never use!

Multiple pictures to follow as I know the Pelicanites like the pictures!

The Ferrari is not mine by the way.

bodmin · 10-12-2013, 09:48 PM

bodmin · 10-12-2013, 10:05 PM

Tail light dismantle:

Rear Suspension / Brakes

bodmin · 10-12-2013, 10:16 PM

And finally unashamedly showing off my new toy

:

Concestor0 · Concestor0's Garage

Wow, gyrocopters have come a long way. That would be great for my 100km commute to the airport.

I have an aviation background along with some non-commercial helicopter experience but I've never flown a gyrocopter. Do owners generally still use airports or do they, to some extent operate them as you would a helicopter?

The car looks great and regarding your passion for tools "the right tool for the job" is always good advice and helps us enjoy the time invested in our hobbies.

4flyboy · 4flyboy's Garage

I've always been intrigued by gyrocopters.....so incredibly safe!

I've never seen one so modern or cool. What's cruise, fuel burn, range and T.O. distance at gross?

Very very neat....S.

bodmin · 10-13-2013, 06:58 AM

Quote:

Originally Posted by Concestor0

Wow, gyrocopters have come a long way. That would be great for my 100km commute to the airport.

I have an aviation background along with some non-commercial helicopter experience but I've never flown a gyrocopter. Do owners generally still use airports or do they, to some extent operate them as you would a helicopter?

The car looks great and regarding your passion for tools "the right tool for the job" is always good advice and helps us enjoy the time invested in our hobbies.

I generally use hard runways for the Gyro. A Gyro only needs 15 - 50 feet for landing, but take off is a completely different issue. Depending on weight, wind, temperature, surface, slope, pre-rotation RPM, etc take off can be anything from 150 feet - 450 feet, and then some to clear obstacles. I fly for recreation only.

I have flown both fixed wing and helicopters, but enjoy the Gyro more than anything else. I would highly recommend them, especially the new generation models available from AutoGyro (German), and Magni (Italian). There are a few US models, but I'm not familiar with them.

bodmin · 10-13-2013, 07:06 AM

Quote:

Originally Posted by 4flyboy

I've always been intrigued by gyrocopters.....so incredibly safe!

I've never seen one so modern or cool. What's cruise, fuel burn, range and T.O. distance at gross?

Very very neat....S.

Perhaps the Gyro should be in a different thread. However (briefly) model is a Cavalon available from AutoGyro

AutoGyro - Cavalon

Cruise is 80 - 85 mph, VNE 100 mph, Fuel burn 15 ltr/hr (solo), 20 ltr/hr (dual), Tank capacity 100 lts, Max TOW 500kg (560kg applied for), Empty weight 298 kg. Cost delivered around £90k ($144k)
Buzz factor - exceptional!!

bodmin · 10-13-2013, 07:16 AM

Quote:

Originally Posted by bodmin

Perhaps the Gyro should be in a different thread. However (briefly) model is a Cavalon available from AutoGyro

AutoGyro - Cavalon

Cruise is 80 - 85 mph, VNE 100 mph, Fuel burn 15 ltr/hr (solo), 20 ltr/hr (dual), Tank capacity 100 lts, Max TOW 500kg (560kg applied for), Empty weight 298 kg. Cost delivered around £90k ($144k)
Buzz factor - exceptional!!

I should also have mentioned it is fitted with Rotax 914 ULS turbocharged motor.

bodmin · 10-13-2013, 07:35 AM

Quote:

Originally Posted by bodmin

I should also have mentioned it is fitted with Rotax 914 ULS turbocharged motor.

Here's a link to the brochure - some common interest for 911 fans:

http://www.auto-gyro.com/chameleon/public/689d897e-bc13-ba42-83f7-5c9c3b926fff/Brochure_Cavalon_ENG.pdf