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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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 Posted: Thu Dec 04, 2008 10:57 pm Post subject: Engine Out (Worklog with photos/ 56K unfriendly) |
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Have had the car (81 932) for nearlly 2 years now and besides a few hoses and a head gasket it has been really fun as a daily driver. The car just handles so well around turns and pulls along swiftly.
However one day i was coming home from work when all of a sudden i heard a nasty clunk noise with a loud ticking noise following a few seconds later.
Pulled over got the car going again (running rough as guts) and managed to limp her home.
After a few cr and leak down tests it was clear that i had no compression in the first cylinder and that something wasn't right with the valves.
The valves doesn't seem to be bent or anything as the clearance is fine but somethings not right there.
Remember seeing a pic floshos head a while back and a piece of the valve had broken off.
Well anyway after the nightmare of replacing the head gasket with the engine in the car this time i have decided to pull the engine 
Bought a engine hoist from super cheap auto for $300 and i was ready to go.
After two days of pulling parts off and spending many of my hours under the car the engine finally decided to seperate as i manouvered it out of the car and onto an engine stand.
These engines are so slanted that it wanted to constantly tip the hoist over.
Well its out now and i can begin stripping it down to find out the problem.
Also to my dissapointment the clutch seems to be on its last few mm's 
so thats something else i have to attend to.
Just thought i'd open this post as a worklog to keep track of my work and keep myself motivated as i become very lazy at times 
Feel free to comment or ask questions.
And below are some action shots i took whilst pulling the engine.
 
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1981 924 turbo (daily driver) |
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Chrenan
Joined: 15 Jan 2003
Posts: 3903
Location: Canada
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| Posted: Fri Dec 05, 2008 12:59 am Post subject: |
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Nice pics, looks like you've been busy on the 931!
Let me be the first to say, what the f**k, you've been holding out on us! I demand immediate pictures of the other projects in that garage, 356 coupe, 356 cab, 914, and did I see and early 911 in there too! What the hell, stop being such a tease. The garage itself looks cool, post up some pics of that too. Everyone love car porn!
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1987 951 - M193 Version for Japan |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Fri Dec 05, 2008 3:21 am Post subject: |
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Congrats, man, look forward to doing the same this winter.
Was it fun?? I see you have the x-member out, did you consider dropping it instead of lifting? I just did it that way on a parts car, and boy was it easy. . .
And ditto to Chrenan, you are a big old holdout.
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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| Posted: Mon Dec 08, 2008 10:06 pm Post subject: |
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A weekend away from the 24 has done me wonders, i'm just so relaxed at the moment.
The workshop isn't mine but my fathers, whom restores classic porsches for work and as a hobby. I just try and sneak my 24 in there from time to time to work on it.
| Quote: | | Was it fun?? I see you have the x-member out, did you consider dropping it instead of lifting? I just did it that way on a parts car, and boy was it easy. . . |
Heaps of fun enjoyed every minute of it 
Interesting you bring that up cause i was under the impression that these engines were designed to come out the top (from searching thru the board).
Which i thought was strange as most porsche engines r dropped and taken out.
Could've saved myself $300
The main reason i went with this approach was that i didnt have large enough stands to get enough room to get the engine out from underneath plus the engine is very imbalanced and hard to balance on a jack etc.
Well with the engine on its stand i decided to work on it this arvo.
Pulled nearlly everything off that needs to come off to remove the head.
Soooooo much easier to work on the engine with it out rather than in the engine bay. Had the radio cranking and was working away
Will pull the head 2moro and hopefully find out what the problem is.
Just a few more shots of the engine before and after:
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Rich H
Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK
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| Posted: Tue Dec 09, 2008 1:12 am Post subject: |
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Can you please take a pic of the exhaust manifold from below?
We need to find out if the bolt on the back of the turbo flange is accessible from below and if so how hard is it to get to.
Ta
Rich
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec |
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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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| Posted: Tue Dec 09, 2008 12:06 pm Post subject: |
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K not a problem just charging the digital camera now so i'll get the pics up tonight
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Rich H
Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK
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| Posted: Tue Dec 09, 2008 6:30 pm Post subject: |
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Thanks!
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec |
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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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| Posted: Tue Dec 09, 2008 8:42 pm Post subject: |
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Here are some pics of the exhaust manifold and turbo with the mounting bracket.
Hope these help
If your talking about the allan key bolt which faces downards and connects the turbo to the manifold you should be able to take it off. The main problem is that once you take it off the turbo still doesnt come off unless you take of the four bolts which connect it up to the block. Because the bracket is wedged in their.
Hope im making any sense and good luck.
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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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| Posted: Wed Dec 10, 2008 9:12 pm Post subject: |
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Well the cylinder head is off and before i even get to examine the head i notice something funny.
Cant believe it my 1 month old head gasket has blown a piece from cylinder 1 -2.
Obviously the extra compression was to much to handle and even the other sections between the other cylinders were on their way out to.
I guess its some what good news as its nothing major.
Gonna search the board for stronger gaskets cause i dont wanna replace my head gaskey every month what do u guys recommend?
Also heres some pics of the cylinder head and the doomed head gasket.
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Rich H
Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK
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| Posted: Wed Dec 10, 2008 9:36 pm Post subject: |
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Thanks for the pic, that's exactly the one we need to get to. Just need to get the head off as the gasket has gone.
Looks like your head has some fretting on number 4 around the fire ring?
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Thu Dec 11, 2008 2:33 am Post subject: |
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Bummer. Was that with factory head bolts? How much boost?
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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| Posted: Thu Dec 11, 2008 9:45 am Post subject: |
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Yeah factory bolts and stock boost, only running a slightly higher comp of 8.7 but cant believe this has happened already.
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Thu Dec 11, 2008 9:57 am Post subject: |
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Drag, what happened? Is there a problem with the head?
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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Paul
Joined: 02 Nov 2002
Posts: 9491
Location: Southeast Wisconsin
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| Posted: Thu Dec 11, 2008 12:38 pm Post subject: |
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Make sure the area between 1 and 2 on the head is checked for height, it may need to be welded and machined.
What do the tops and sides of the pistons look like near the gasket's damaged area?
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White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy. |
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elitejaso
Joined: 24 Jul 2007
Posts: 143
Location: Melbourne
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| Posted: Fri Dec 19, 2008 8:23 pm Post subject: |
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| Quote: | | Drag, what happened? Is there a problem with the head? |
Drag? Do u mean wat happened before the car died?
Just spooling up in 4th gear when i heard a bang and pulled over.
Besides the head been shaved a fraction its all good, no cracks or nothing.
Paul the head height is constant throughout the whole head and checked the piston especially 1 & 2 and they're fine.
Thinking maybe i just got a dodgey head gasket, just gonna get a stronger head gasket and hope all is well.
Only started working on the 24 today since a pulled it out and apart, been very lazy 
Painted and cleaned the block along with a few other lines. So its looking good. Now i gotta go searching for some parts before i can move ahead.
Just gonna right up a quick to do list so i dont forget anything.
-get oil lines fixed recrimmped, also install new oil filter
-get fly wheel reground and buy new clutch disc
-buy stronger h. gasket (that will last longer than a month)
-clean up head and gaskets
-remove and repaint brake cylinder
-fix leaky slave cylinder
-refresh turbo (or just main turbo bearing, a bit of play)
-paint engine bay
-put engine back together and in car
-get her running and then
Just got my work roster for january and am working nearly everyday besides my b'day and australia day so i'll have no time to get the 24 workin
But will b cashed up  (i'm thinking cgt body-kit)
I'll try and sneak in a few weekends work and have her purring some time in feb, if all goes to plan.
Wish me luck and i'll keep u all posted.
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