1st Engine Drop Done & Found a Few PO Issues!
 

Hi, just completed my first engine drop on my 77 Carrera 3.0 to deal with the triangle of death etc. and found a few problems/mysteries once I had the motor out.
First though the required photo.
http://forums.pelicanparts.com/uploa...1376463824.jpg
Plus one of my helper (Gary Smith) and it was his first 911 Drop Too!

http://forums.pelicanparts.com/uploa...1376463989.jpg

Looking at the motor once out I'd like some opinions on the following please!

Clutch Release bearing is it supposed to have this much sideways play? You can see the wear on the disc.

http://forums.pelicanparts.com/uploa...1376465012.jpg

The engine mounting crossbar is bent and has an old rusted crack is this repairable?

http://forums.pelicanparts.com/uploa...1376465252.jpg

Airbox has signs of being glued Dammmnnnn!

http://forums.pelicanparts.com/uploa...1376465452.jpg

And what goes on this open pipe?
http://forums.pelicanparts.com/uploa...1376465670.jpg


What is this I cannot find a wire and plug for it?
http://forums.pelicanparts.com/uploa...1376465846.jpg
What is this it looks like a oil catch tube/can and looks like a hose should be connected at the back of it.

http://forums.pelicanparts.com/uploa...1376466044.jpg

Many thanks in advance.
Cheers
Bill

first of all: congrats!
I still have that before me.

1. I cant say.

2. the cross bar: better replace it with a used but good one and then maybe weld some stiffening in that area (a stiffened racing cross bar may be too expensive for the "job").

3. the airbox seems to have been damaged due to classic "blow up".
Is there a pop-off valve mounted (inside, belof airfilter)?

4. there should be a hose stuck to it, going to the airbox backside, imho to the extra airflow regulator (German: Zusatzluftschieber).

5. + 6. cannot say, sorry.

Flojo,

I do have a pop off valve but its still in its protective wrapping.
Im not sure this is the box to install it to though.

Cheers
Bill

The air box looks normal. My brand new one from Porsche had pink glue residue like that and is used to seal it up. The fitting on the side I think connects to the charcoal filter on mine unless yours does not have this filter.
The other pics are too close and I can't get a frame of reference to help.

I'd be most concerned about that engine mount. If the car was hit at some point and that broke the car may be tweaked. You get a replacement and the bolt holes to mount the engine may not line up.

The last picture shows the oil drain pipe for the air box. There should be a hose from that piece to the bottom of the air box. Oil that accumulates in the air box from the breather tube drips out of the bottom of the fitting. You will find the end of the tube has a rubber flap that lets the oil drip out by the oil cooler, but prevents air from entering. Not one of my favorite designs, purposely dripping oil on the engine.

http://forums.pelicanparts.com/uploa...1376481621.jpg

http://forums.pelicanparts.com/uploa...1376481637.jpg

E Sully,
Thanks for identifying this for me, does it connect by hose to the open pipe in the bottom of the airbox in picture 6?

Cheers
Bill

no it is a drain system that at some point the factory plugged.

the air box nipple - you probably disconnected the hose that goes to it when you dropped engine, it is a braided fabric wrapped hose (relates to the carbon canister fuel vapor system).

The duck-bill oil catch. German engineering at its worst.

Picture 6, according to the PET I posted a picture of in my other post shows item 26, plug, going on the open pipe.

Underneath all the gunk you see in your photo:

http://forums.pelicanparts.com/uploa...1376512832.jpg


This thing lives:

http://forums.pelicanparts.com/uploa...1376512861.jpg

What I want to know is what did you use to tip the car, I mean the entire garage, on its side in order to take the first picture? :D

Southern hemisphere........
 

Ronnie,

If you have been to Australia and live there long enough, you'll experience a different gravitational pull. BTW, he is located down under. Plus they drive on the different side of the road. Everything seems to look different but that's normal to them.

Tony

What Tony said plus..........
Water goes down the drain in the opposite direction to yours......

Cheers
Bill

Another PO issue is the shift coupling have a look at this!
http://forums.pelicanparts.com/uploa...1377776062.jpg
http://forums.pelicanparts.com/uploa...1377776122.jpg
Amazingly I was able to shift pretty well with a very light touch.
I had already bought new bushings from.......

http://forums.pelicanparts.com/uploa...1377776315.jpg
http://forums.pelicanparts.com/uploa...1377776391.jpg

Yet another find is the pretty disgusting deposits inside the intake manifolds.
What is the best way to remove this?
Is this caused by a previous oil over fill?

http://forums.pelicanparts.com/uploa...1377776677.jpg
http://forums.pelicanparts.com/uploa...1377776720.jpg
Cheers
Bill

I am not sure if there was an oil over-fill situation that could have caused that issue on the intake runners. However, I think that your best bet is to clean clean clean the intake runners (as well as the other items in the area) with carb cleaner and a tooth-brush. I would also consider having the injectors flow pattern tested - since you're far enough into the job. While you're in there, replace the injector sleeves, o-rings and such; perhaps a deferred maintenence item that the PO never did.

Congrats on the drop. Many people do not have the balls to take on that amount of work.

Regarding the engine mount bar, I think it's very unlikely that the car was hit. My understanding is that this is pretty common, as that whole thing is threaded and the bolt bonds to the threads, causing the exact crack you see. It happened to me when I went to replace my engine mounts.

If you're handy with a welder, you can fix and put a gusset there to reinforce...or buy a new engine mount bar and assemble with antiseize...or do what I did when I found the exact same problem, and get the racy, reinforced one from rennline.

Pelican Parts - Product Information: PEL-RENM01B-RS