Replacing broken head studs/reinstalling cylinders

[medarwin]

Hello, the saga continues. I am finally down to the case (which I am not splitting) and believe I have erred in my dis-assembly. I did not want to pull the pistons (don't ask why) so pulled the cylinders to get to the studs. Today's project is to remove all the lower studs, broken and otherwise and install the new studs. After that, re-assebling the cylinders onto the pistons. However, in searching for a ring compressor to reiinstall the pistons I cannot find one like the one in Wayne's book. WHich looked like it would be easy to use to re-install the cylinders onto the pistons. I am now thinking I would have been a LOT smarter to take out the pistons in the cylinders and not have to worry about re-inserting them. Too late for that though.

Anyone have any advice at this stage? I am also concerned about fouling up the timing chain as I turn the engine over to expose the pistons. All new ground for me. This was originally a quest to fix an oil leak in the Triangle and has now been a 3 month project (so far) and racked up an impressive $$ figure in parts and tools.

Anyone?
Thanks, Darwin

[Dpmulvan]

What kind of cylinders do you have?? Alusil or nikasil? It makes a difference

[boyt911sc]

Darwin,

You are committing a serious mistake by not overcoming your anxiety. There is nothing difficult in your engine rebuilding process that you or a typical DIYer could not overcome. All you have to do is keep an open mind and listen to people who have done this task many times over. There were thirty nine (39) Pelicanparts members who attended an introduction to Engine Rebuilding Classes last month that were in similar mental frame of mind like you.

Contact anyone of them and inquire their experiences after attending the sessions. You are making this engine rebuilding process more difficult than it is. There is nothing to it if you want to know and learn how to do it right. Your ignorance could be easily changed to knowledge if you are willing to LISTEN and keep an open mind. Wish you the best.

Tony

[DRACO A5OG]

Brother Darwin,

Where are you located?

Maybe a Pelican that did a rebuild could give you some guidance?

My 2 cents, get the WISECO ring compressor tool that is the diameter of your piston


Remove the piston via removal of the retainer, being absolutely sure it does not spring into the engine ( so important ), position the rings and use the above compressor to place the piston into the cylinder, leaving the skirt exposed so you can put both the cylinder/s and piston/s back on the rod/s.

A small screw driver and your finger nail will do just fine to install the retainer clip. Do not worry just make sure engine holes are plugged up with blue shop towel, do not use white paper towels they tend to shed.I know a bit OCD but better safe then sorry.

You can try to use Wayne's recommended tool but it is not too easy and you may snag a ring or scrapers, as you try to push the cylinder down over the two rings and two scrapers and damage it as you are doing it kind of blind. Again, my 2 cents and experience as I have both tools.

Here are my experiences: Part Trois: 3.4L Build, The Journey

BTW, I had to redo my #6 because I stripped one of my studs when I removed it without using heat and damaged the case. I made the repair to the case and reinstalled it by doing the above process.

[john walker's workshop]

Search HAZET ring compressor. The cat's azz.

[john walker's workshop]

[medarwin]

Not sure which cylinders are on it. Below is a pic of the part #. Does anyone know the size of the cylinders on a stock USA SC 3.0L? My micrometer took a walk and is hiding in my garage somewhere. BTW, I was able to remove 6 lower head studs today using my beak extractor, lots of patience, map gas and an air impact. Amazing how they differ in tenacity. SOme came out easily and others required an act of congress. Next 6 tomorrow. Anyone ever use one of the old studs with grooves cut as a thread chaser?

[Trackrash]

OK, it sounds like you have basic mechanical experience, but are not familiar with our air cooled gems.

If you don't have Wayne's How to rebuild Porsche 911 motors or a Work Shop Manual, now is the time to get one and spend some time reading.

FWIW SC motors have a 95mm bore. The tolerance for wear on the cylinders is very tight. 0.002" taper or ovality and the cylinder is worn out.

Now you have some choices on your cylinders, BUT it depends on the manufacturer.

Here is a Mahle nicasil cylinder.

[Eagledriver]

Hi Darwin,

You haven’t done anything wrong yet. You can either leave the pistons on and find a ring compressor to install the cylinders or take the pistons off and install them on the bench. I recommend the later. You don’t need to worry about turning the engine over. Since the heads are off, you’ll have to time the cams when you put it back together.

You have Alusil cylinders. It would be a good idea to measure the piston to cylinder clearance and the ring gaps as well as the piston ring clearance in their grooves. You likely can reuse everything, but it’s good to check.

-Andy

[Eagledriver]

If you take the pistons off, heat them slightly with a heat gun or propane torch. The pins will slide right out if you do.