1985/2 2.5L rebuild - block to bearing cap alignment
 

Rebuilding a 1985/2 2.5L engine. The main bearing cap does not seem to align well with the block, as there is a noticeable ridge between the block and the cap at the front of the engine. This is where the oil pump is supposed to mount. The Porsche manual mentions something about a fingernail test, but doesn’t go into details. From the way things are drilled, it looks as if there should be a second alignment bushing at the front of the engine, in addition to the one at the rear. The PET catalog shows only one, at the rear. I have considered quickly bolting the oil pump in place prior to torquing the bearing cap in place – but I am worried about the working time of the block to cap sealant. The shop manuals mention flattening the area with a stone – which seems like a risky proposition. Any help or experience out there?

hehehehehe been there......

Stick the crank girdle in the freezer....... she will shrink a couple of thousand.

Then line it up and bolt her up........ don't touch it with a stone unless you know what you are doing...

P.S in regards to the missing alignment pin. You are correct. It is thought that it could in effect contribute to #2 rod bearing letting go. Some of the high performance shops will add another pin then line bore it etc........ but then you have other machine work to add to your list... so .... not really worth it for a street car.