924Board.org

[garthfan]

Well, the engine speed sensors turned out to be the problem. They were simply in backwards. Switched them around, turned the key, pushed the ignition button...and she fired up for the first time in over two months!!! YAY!!!

Man, this engine rebuild was an experience. I've done my share of American big-blocks and even some "American" four and six-bangers, but I've never done anything like this motor before. It was definitely different.

But, it's done, it runs. I just need to realign the steering, get a front-end alignment and bleed the brakes/clutch system.

Here's the list of what I did for those interested:

Basically started by tearing down the engine and inspecting all the various pieces to see what needed replacing and what didn't. Cam and lifters were replaced in 2002, so I didn't touch them.

New rings, rod bearings, oil pan gasket, head gasket, intake, mass air-flow sensor, cam-assembly gaskets (front, lower and rear), clutch assembly, release-fork, throw-out bearing, new nuts and bolts everywhere, new plastic front-cover assembly. Also put in a rebuilt steering rack, new tie rods and tie rod ends. New starter, new engine-speed sensor, new vacuum fittings in various places. New clutch master cylinder. New cap, rotor, wires, plugs. Oil filter and fresh fluids pretty much finished it off.

For those who will jump right on this one: The front-of-engine service was done in February of this year, so obviously I reused all the same pieces as far as the fairly new water pump, timing belt, balance belt, seals and tensioner. Just need to take it down and have it tensioned "properly."

Anyway, this was sometimes fun, sometimes aggravating, sometimes exciting and sometimes heartbreaking, but it was all worth it when I heard her fire up for the first time. Thanks for all the help you guys provided along the way!!!
_________________
1987 924S - Was a daily driver...now it's GONE! *sniff*
1986 944 N/A Guards Red
1996 VW Jetta Grocery-Getter
1995 Saab 900S Winter-Driving-Feeling-of-Security-Vehicle

[Neil924]

Good job! It's a heck of a lot more than I could do! Hip Hip Horray!!!

[macBdog]

I love a happy ending! Must be great to hear that engine noise after all the hard work.
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1979 931 with a 350 chev
1973 911E with EFI

[924guy]

Congrats!!! sometimes hard work really pays off! so hows it running??
_________________
Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha

[-nick]

Great, now you'll have a solid platform for autocross season in the spring

Congrats! Nothing like a job well done.

nick