924Board.org

tyfighter123 · Joined: 19 Jan 2010 Posts: 551 Location: Colorado

Hey guys. I have been at this car for years now. You can see my original post at http://www.924board.org/viewtopic.php?t=33506&highlight=tylers

Pictures are gone but I will be updating them soon. But here is the before picture...

and the after.....

the interior before.....

and the after....

engine bay before.....

engine bay after....

I will be updating my thread with everything that I have done but it has been a few years of hours and hours of time.

I just rebuilt the engine with...
Diamond custom pistons 87.5mm (10.5:1)
Integral grind stage 1 cam
Group make/buy of new solid lifters.
Big valve kit for head that was ported and port matched
All new gaskets
Arp head studs and Rod bolts
All engine machining, lightened flywheel, balancing, etc.

Needless to say I went all out on the engine as I have on the whole car. Well I got it all put back together and fired it right up. It started and I ran it for 20 mins to break it in. Everything was fine other than I did notice that the intake was running very cold? I found out that I had the cold start valve plugged into the warm up regulator and the warm up regulator eletric plug into the cold start valve. It was just dumping fuel into the engine. So I got that all sorted. Well I was out yesterday adjusting the fuel mixture because it was leaning out after 3000 RPM's so I would drive it and check the AFR (I installed an inovate gauge) stop adjust the mixture a 1/8th of a turn and drive it again. Well it stalled on me and I could not get it to start. Most likely because it was flooded. It would turn over it just would not fire. Well we push started it and got it to run, drove down the street and it quit. Sounded like it threw a rod. So now I have to take the engine back out dissasemble it and see what went wrong. Very frustrating. Why do these cars have to be so addicting and difficult to get to run

_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)

Luvmy80-924 · Joined: 15 Mar 2012 Posts: 56 Location: PA

Nice job, Love the color! With the cold start injector fireing all the time you could have wiped a bearing out, no? They certainly are addicting but worth it I think. I just had mine out and wit the cold air outside it runs like it got a shot of nitro. You will get it figured out and that car looks like years of enjoyment.
_________________
1980 924 N/A Everyday Driver
1986 930
And now a 1980 931

morghen · Joined: 21 Jan 2005 Posts: 9095 Location: Romania

wow what a turn around. i think this is the worst 924 i've seen that turned into one the best 924s i've seen

now onto your engine problem...
if you dumped fuel into the engine during breaking in you for sure got ALOT of fuel into the oil....that means you had no lubrication or very little lubrication....that means...well...alot of money

if you indeed filled the oil with gas, you broke it in like that and then drove it some more...you might be in for quite some damage.
_________________
Supercharger and EFI kits
https://www.the924.com

CorsePerVita · Joined: 25 Jul 2008 Posts: 1992 Location: Redmond, Oregon

_________________
- 1977 Porsche 924 2.0 N/A (Trackday Project)
- 1979 Porsche 924 2.0 N/A (The other daily)
- 1980 Porsche 931 (Daily)
- 1987 Lamborghini Jalpa
- 1999 Ducati 900SS

tyfighter123 · Joined: 19 Jan 2010 Posts: 551 Location: Colorado

I changed the oil after break in, and then again when I could not get it started because it was flooding I changed the oil again to make sure I hadn't washed the engine with fuel. The oil came out after break in very clean with no gas smell. The second change it had a small fuel smell but was not bad and did not run it long with the oil. So I hope nothing happened because of fuel being in the oil. I will have the engine out this week and will let you guys know what the point of failure was!

morghen thanks for the complement. I would like to get some turbo twist wheels like yours they look awesome as well as your recent body work very nice!

CorsePerVita, thanks coming from "Darth" means a lot! How is your project coming?
_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

How's your oil pressure?

Have you popped the valve cover to check the valve clearances?

Pulling a spark Plug wire one cylinder at a time could help you determine which cylinder sounds off. You may just have badly fowled plugs.
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

pmcaya2 · Joined: 24 Nov 2005 Posts: 191 Location: Scio, NY USA

First of all - beautiful job on the car! Sorry about the engine problems, but there are a few things to check:
1) double check timing belt alignment to make sure crank-cam-and distributor are working together (see "how to" section) Make sure that #1 piston is at TDC when you do the check
2) check tappet clearances per Haynes manual and other posts on this forum
3) make sure there are no vacuum leaks in the air duct between the distributor and intake - the injectors depend on vacuum to raise the distributor plate.
4) pull the plugs and check the compression - a thrown rod should make a difference - hopefully, that's not the problem.

The 924 has a very durable engine when its set up correctly, but it does has some quirks - especially in the timing belt alignment. Mine has 192 K mi and is running strong, so stick with it. Hope this helps. - Peter

tyfighter123 · Joined: 19 Jan 2010 Posts: 551 Location: Colorado

morghen · Joined: 21 Jan 2005 Posts: 9095 Location: Romania

i guess you can only find out if you open the engine...good luck !

oh and i think the D90 wheels you have on are a better(read as perfect - look at rasta's car) choice than the twists on a narrow body..but thats just me. It depends on how much you want to go out of the factory recipe. I have a narrow body 932 that i'm slowly rebuilding and i'm going to keep the spiderweb wheels for the winter on it and use the D90s in the summer.
_________________
Supercharger and EFI kits
https://www.the924.com

tyfighter123 · Joined: 19 Jan 2010 Posts: 551 Location: Colorado

Well engine is out.....

Took me a little over 4 hours to get it all out. I took the oil pan off expecting to see huge damage. When I looked in there was no signs of damage at all. There were not flakes of metal anywhere, not even in the oil I drained out this morning. I looked at the walls of the cylinders as best I can with the crank and pistons in, and there were not signs of wear at all. I turned the crank over by hand and it turns just fine.

Next I will have to check the bearings...........
_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)

daniel · Joined: 18 Jun 2009 Posts: 686 Location: Sydney, Australia

From what you've described I doubt their would be any internal damage at all. Sounds like all your issue are in the injection. While your there, pop the caps of the rods to check how the big ends are breaking in, if all is ok just put her back. I wouldnt pull the pistons unless there is scoring on the bore, but you can if you want. Provided you dont R&R the rings or swap them between cylinders it shouldnt have any affect at this early stage. Also, pull the cam and lifters, make sure everything is even and happy. If you've got plenty of money for head gaskets pull the head too.

Once all is back together and running, get her dynoed. So easy to see whats going on when shes on a dyno.

BTW, I dont need to tell you how good your car looks man. Top marks, when you starting on mine!
_________________
Over the top of skyline, total brake failure.... hit the wall at over 200 kp/h at the dipper, so anyone who has to brake for the esses is a pussy.
1977.5 Race Car, CAMS Group S Spec
1989 944 Cabriolet

morghen · Joined: 21 Jan 2005 Posts: 9095 Location: Romania

do you have a video recording of the engine making that noise you're looking for?
_________________
Supercharger and EFI kits
https://www.the924.com

Luvmy80-924 · Joined: 15 Mar 2012 Posts: 56 Location: PA

This may sound stupid but I had a noise in mine that I would have bet was a wrist pin or rod bearing. I was useing a screw driver up to my ear on different spots on the engine and bumped a spark plug wire and the noise changed. Here it was a loose spark plug and it was leaking compression. I never heard a noise like that from a plug, just don't overlook the simple problems it's very easy to do.
_________________
1980 924 N/A Everyday Driver
1986 930
And now a 1980 931

Fifty50Plus · Posted: Wed Oct 03, 2012 12:53 am Post subject:

I bought a Mercedes Benz 6 cylinder for cheap because it had a bad rod knock. Or so the mechanic and owner thought. It turned out to be a bad fuel distributor (same type as the 924) that was leaning out one cylinder and causing detonation in one cylinder.
If you pull the head, look at the color on the piston tops. A lean burn/knock will be a different color than the others.
No metal and no blue colored rod end cap says your bearings are fine.
BOL.
Chuck
_________________
1979 924 NA race car H-Prod SCCA
1982 924 NA race car - Sold
1981 924 Turbo sold
1982 924 Turbo sold
1972 911 E race car - traded for Cayenne Diesel
1975 914 1.8 Building for H-Prod SCCA

tyfighter123 · Joined: 19 Jan 2010 Posts: 551 Location: Colorado

I looked at the rod bearings last night one at a time and they all looked good. They had a little bit of normal wear. I will try and post pictures of them. I also looked at the mains and samething. slight smooth wear. Again no metal flakes in the oil. What do you guys suggest I do? Offer still stands to have someone out to help and I will put them up at the marriott

_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)