924Board.org

sword70

Hi guys, i have finaly got my replacement engine for my 1979 924 Turbo and am getting it al ready to fit.
I have been advised that the best method is to fit the Turbo before fitting this engine as it is realy difficult to do so when engine is in.

What i realy need is you GOD like wisdom and experience to let me know what bits to fit first to make the whole job that bit easier in the long run.

I currently have the engine with cylinder head and block etc all complete and timing belt and cover fitted, also the clutch and bell housing are all fitted but have left the pressure plate loose to help in lining up later when refitting engine.

If any of you guys has any pictures of say an equivalent engine prior to fitting on an engine stand that would be very helpfull as i did not remove this engine and just got a few boxes of bits so a bit of insight into the finished look would help in routing any pipes and cabels.

Thanks in advance to any help.

mrgtturbo · Joined: 06 Jan 2003 Posts: 526 Location: Skowhegan, ME

I have no advice to give you, but I can tell you this.
I found taking the turbo out, and puting it back in to be a B**CH of a job.
I don't blame you for looking for an easier way.
Good luck.
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81' 931

sword70 · Posted: Mon Jan 05, 2004 10:14 am Post subject:

Cheers mate, i have been looking through some of the probs youve had and see that you are having fun with you Porsche too.
All the advice you had about the refitting of the flywheel helped me alot as i got my engine in a box of bits and my new one without a flywhell, all Haynes manual said was to scribe it before removal to ensure correct refitting, great if its all going onto the sam eengine but no help to me.

Luckily i was reading your post and the help you got was amazing and helped me today to succesfully install my flywheel and clutch.

I was a self taught mechanic/bodyworker for 10 years so am pretty confident with these matters but each car has its little surprises and theres no substitute for the experience of enthusiasts and same make mechanics.

Hope your Porsche is all sorted soon.

Paul · Posted: Mon Jan 05, 2004 12:43 pm Post subject:

You really want to install the oil filter adaptor (complete with oil cooler), exhaust manifold, and turbo before you install the motor. The J pipe and wastegate must wait until the motor is in.

Make sure you follow the turbo mounting instructions exactly.

Lizard · Posted: Mon Jan 05, 2004 1:16 pm Post subject:

pulling and putting in the turbo w/ engine in isn't hard just time consuming, really time consuming, if you have the engine out just install it on the engine then install it all as one
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3 928s,

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

sword,

I've got a '79 turbo engine currently on a stand. I took some photos before I disassembled it and I'll see what the pictures look like, and will post them later today.

If your question is essentially "as an assembly, what should be put together before hoisting it back into the car?", my answer would be "everything". Put your entire clutch/pressure plate/bellhousing all back together and bolted in place, and put that puppy back in as a "whole". Bolt on the oil filter adapter and cooler/hoses. Bolt on both manifolds and the turbo. Only one person on this board (that I'm aware of) believes that an in-car turbo replacement isn't a pain. It makes no sense to try and "piece-meal" the motor back together in the engine bay.
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'79 Eurospec 931

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

Click on any of these thumbnail photos below to go to a photo gallery of my project. Once there, click on the small photos for larger images. Most of them were taken before I got a good digital camera, but you should be able to make sense of everything. I had really planned on taking "decent" photos on re-assembly when everything would be clean, but thought that some "before" photos might help if I needed to compare things. Hope they help you.

.._..

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'79 Eurospec 931

sword70 · Posted: Wed Jan 07, 2004 9:17 am Post subject:

That is absolutely brilliant, thanks for the pics, just what i was after.

I have taken out and refitted many engines in the past but have not done much work on cars over the last 4 years so am a bit rusty and i suppose confidence is not what it was so when delaing with the engine refit after only ever seeing it as a box of bits and already well stripped down was a bit difficult to imagine the whole engine and the best way to put it back in.

All i have to do now is to repair a snapped stud on the turbo and get some gaskets and i am goint to get on rebuilding to the same point as your pictures and hire an engine hoist and go for it now.

My car was last used on the road by the previous owner over 4 years ago so i still have a long way to go but this is going to be a big step forward.

The engine i purchased for my car was sourced after someone contacted me in the UK after seeing a post i made on this board and £500 GBP and a few weeks later i now have a low mileage service historyed engine for my new toy so a bit of time, a few cups of coffee and loads of cigarettes and i should be one giant step closer to driving a car that i have wanted since i was 12 back in 1982.
I will try and upload some pics to my web space so you can see what my toy is like and monitor the progress.

Thanks again the pics are a life saver.

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

Post again, or e-mail me if you need/want close-ups of anything in particular. I may have them already, just not on the web site. On the other hand, the engine still hasn't been re-assembled, so if you need a photo of something I don't have already, you may be out of luck for the time being. Never hurts to ask...

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'79 Eurospec 931

sword70 · Posted: Wed Jan 07, 2004 9:48 am Post subject:

Your pictures have answered so many questions i had already i guess now its going to be down to the weekend when i get stuck into it that i will realy know whats what and what if any info i will need but rest assured i will be posting agian on this topic.

All i have to do is get my wifes 1970 Beetle i'm restoring out of my garage to give me some room to work and i'm going to go at it full steam.

sword70 · Posted: Thu Jan 08, 2004 12:13 am Post subject:

Am i doing the right thing by leaving the clutch plate loose for refitting to ease in aligning the engine when putting it back in and tightening it when all in place through the inspection cover.

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

This is the first time I've pulled/replaced the engine. I'm going to reassemble everything, including the clutch components. I think the alignment tool is used to keep the components all lined up straight so when the engine is put back in place, you can take out the tool and push the drive shaft/torque tube/transmission into place. I can't see any advantage to putting the engine assembly back in the car with the bell housing loose. Just sounds like more trouble than it's worth trying to tighten (and properly torque) bolts in confined spaces.
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'79 Eurospec 931

Lizard · Posted: Thu Jan 08, 2004 4:03 am Post subject:

with the pin for the clutch fork shaft it is not worth your trouble to do it with the engine in the car, assemble before install, and at the factory the engine was installed from the bottom, and I am pretty sure the put the engine torque tube and tranny in all at the same time
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3 928s,

sword70 · Posted: Thu Jan 08, 2004 4:04 am Post subject:

I was going to tighten the bell housing all up but just leave the clutch assembly loose as most times ive aligned a clutch on other engines the final mating of engine to gearbox can still be a bit tricky and i hate to put a strain on the clutch so at least with the plates loose i can gently manouvere it together and tighten the bell housing to engine once lined up and finaly through the small hole in the bell housing tighten up the 9 bolts and job done.

Zuffen · Posted: Thu Jan 08, 2004 12:32 pm Post subject:

Hmm it seems to me by my poor memory it was easier to pull the bell housing off and put it back on the torque tube to line up everthing on the shaft, and the motor drops in place without any binding.

All you have to do is stab the shaft into the flywheel bearing and rotate til the bellhousing pins line up. slip the bolts in, rotate the engine til you get the pressure plate holes lined up, but I may be confusing the steps with a 944 engine.

I know when I pulled this 82 931 motor a week ago it was binding on the drive shaft, while trying to get the motor to pull forward and up and have it clear things. I had to drop the crossmember to clear the oil feed and return line and the front of the turbo. If you did that crossmember first you might be able to come straight forward and then up and the reverse when installing.

I would i drop the sway bar and crossmember, remove the rear A-arm point bolts, steering knuckle shaft, the crossmember will drop down enough to stab the bellhousing onto the torque tube.

When I did my motor years ago, I came in fully assembled from the bottom and just got an alignment when the job was done.
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Bob Dodd - 924turbo@cox.net
931 1982, 944 1982 euro, 924S 1988SE, 93 968 tip 06 Silver Cayenne S, 06 Black Cayenne S

I have Way too many cars, parts for the 931,944 and 951