Really Bad Engine Noise
 

My son just called and said his engine started to make a bad noise when he was only a mile from home after an otherwise uneventful 300 mile trip. He drove it the mile then shot a short video before turning it off. I've told him not to start it. We will get it towed to the local independent P-car guy.

It is a early '85 944 with about 87K miles. Hope someone can tell me it is not what I fear it to be.

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Sound like a rod bearing.

That was my first thought.

What are the chances I can get away with just replacing the rod bearings and avoiding a full tear down?

It’s not what you want to hear but imo if a rod bearing has failed you would be foolish not to tear down and thoroughly clean everything.

So here is our dilemma, ...

Other than the engine, it is a really solid car, so we'd like to keep it. That leaves 4 options.

1. Tow it home (16 hour round trip) and rebuild it myself.
2. Pay someone to rebuild it where it is.
3. Tow it home and drop in a used engine (assuming we can source one locally)
4. Pay someone to drop in a used engine where it is (again assuming we can find one there)

As much as I would like to rebuild it myself, I really don't have the time and my son needs a car. A used engine might be the fastest way to get back on the road but we may face other issues down the line and it could end up costing more in the long run than a rebuild. We could go the route of a used engine to keep him on the road while I slowly rebuild the one in the car now. But it could take me a very, very long time as other things would, no doubt, take priority.

Anyone been in this situation and have some words of wisdom?

How about upgrading wyit. Here’s a 1990 944S2 complete running engine/conversion package for $3200. Seems like it is only 4hr away from you and I’m sure John Graves, who is the guy selling it and owner of Just Joshin Porsche 944 Parts, would help with installation (no affiliation)

https://youtu.be/RVf7QnKn66g

Shhhh! It is my son's car and he might read this. ;)

I did reach out to John about a 2.5 NA engine he has on his site. Funny you mentioned him. I bought an aluminum under tray from him a couple years ago and hung on to his card. I came across it just the other day.

I'm not sure its a rod bearing or who knows what, but putting your trust in an over-the-internet tribal diagnosis using a cell phone video is not prudent. Spend a few bucks and have someone do a real diagnosis on it. Then make your decision.

^^^
THIS is the BEST advise so far!

IMHO SmileWavy

OR, do your option #1: Rebuild it yourself. (BTW, I noticed you have a track car same MY and engine w/electronics. PUT that engine in it and take a break from the track. You can thank me later.

I pretty much knew it was a rod bearing as soon as I heard it. I've heard that sound in other cars I've owned. I was hoping against odds that I was wrong.

It will be towed to a local, well respected P-car shop, as soon as the arctic temps ease off enough so my son can dig it out of the snow.

I just started track driving and have 30+ days on track planned for this year. So he can't have my motor. ... unless I were to swap in the S2 motor that 9FF found.

BTW:

The 944S2 engine will not bolt right-up without some work as well as the electronics (DME/ECU) is different and modifying the entire system to console connections.

Not trying to be a putts here, so apologize if it seems that way.

That car in New Orleans (yellow 944) might be the right option as well...you know the one I am addressing here.

Good luck with your endeavor.:)

Yeah, I agree have someone talented look at it. The sound appears bad but send some oil to Blackstone Labs for 25 bucks and if its clean, consider other things that will make that sound. Like a belt that lost a chunk of rubber, or a harmonic pulley that's coming apart, etc. I've been fooled by videos before. Also where are you - might be a member in the area who'd give it a gander if its 300 miles from ya. I would!!

Glenn,

One suggestion i can make is to pick up a Lindsey Racing three piece crossmember , used is fine if you can find one ... it makes rod bearing replacements a lot easier ,especially if you're going to track your car. As for the engine noise, once you drop the oil pan and remove the bearing cap on #2 you'll have your answer !
That clacking sounds familiar ... had a rod bearing go on my Mazda 3, actually sounded a lot worse than yours when i finally parked it and replaced the motor.

A couple of things that can be done
1- pull the plug wires up off the plugs, let just rest on top the plug. While the engine is running using insulated pliers pull each wire off the plug and listen for a change in the noise. If you pull one and the noise changes very noticeably that is the affected cylinder.
2- pull the drain plug and drain the oil through a coffee filter. Any signs of metal isn’t good, and will require oil pan removal for further inspection.
Replacing the bearings isn’t that hard to do, search the forum and you should find a couple of very good write ups on the subject.

If you replace the bearings without doing anything else, you can expect to replace them again after about 10 minutes of running.

Great advice from everyone. I appreciate it.

I was in denial for a time. But I have reached "acceptance" now. I'm in Pittsburgh and the car is with my son in Kalamazoo, MI. We are both, currently, frozen solid. :D

I have changed the rod bearings on my track car so the task is familiar. And from that experience, I see huge value in the Lindsey 3-piece cross member. Its on my list for the track car. But my son's car shouldn't need that level of access very often.

I have narrowed my options. But will wait until we can get it to the shop and get their input before making a decision.

We will either have the shop drop in a used 2.5L or rebuild the original engine. If we go the used route, I'll try to find one near me then change the rod bearings, reseal it and freshen the belts etc. before delivering it to the shop for them to install. I'll then bring the original engine home and rebuild it in my spare time.

For now, we wait for the temps to get back to double digits on the positive side of zero.

Oh, TibetanT I do know of the yellow 944 in New Orleans. It is an option but it is still over a thousand miles from me. And the S2 idea is just fun to think about. Nothing to pursue at this time.

Dear DaddyGlenn - could I suggest to collect the oil and send it to Blackstone?

This might be very interesting. And $28.00. But I might be able to share some of my results, if it helps.

I will start doing that as part of the maintenance of my track car. But for my son's car, I think it is too late.

And in the category for "Best Advice on an Internet Bulletin Board" goes to emoore924! http://forums.pelicanparts.com/suppo...artysmiley.gifhttp://forums.pelicanparts.com/support/smileys/clap.gifhttp://forums.pelicanparts.com/suppo...artysmiley.gifhttp://forums.pelicanparts.com/support/smileys/clap.gif

Had the local shop check it out and they found the noise was coming from the 3 month old alternator. :rolleyes:

New alternator has arrived and will be replaced this weekend. Also doing an oil change and will grab a sample for analysis.

Ah, good move, Dad. I've been fooled briefly by a wide variety of accessories whose failure makes it sound like the engine's melting down. Having an expert look in person was a good move. And now you'll worry less about him because of the new alternator. Just like I worry less about my daughter at college 2200 miles away because I did heavy maintenance on her vehicle last summer. Well done.