By Richard9591 - Thu Oct 13, 2022 9:33 am
- Thu Oct 13, 2022 9:33 am
#176110
I will document a complete engine removal, rebuild and replacement over a number of posts - mainly pictorially with explanations of what I found and what I did. The engine came out originally due to a failing head gasket which happened over a long time but which came to a head when it started hydro locking on startup from cold occasionally. the engine would turn then struggle before firing into life, obviously because coolant was entering a cylinder as the engine cooled but was being ejected when the exhaust valve opens. Something that will only get worse.
The rebuild also gave me the excuse to prep the engine for the new development headers and the intention was to use an engine dyno to evaluate. For various reasons this did not happen and I have used a rear wheel dyno on the finished car instead. Development is ongoing ( I need to sharktune as the engine is now breathing so well the mixture is weak) but the headers are now fitted to two cars. That is another story but I have included a pic as a taster. Anyway they are making an extra 10 bhp and 10ftlb of torque before development so a good start
So. to the rebuild. I am lucky to have a 2 post an 4 post lift in the workshop which makes life much easier. 928 engine bays are packed and there is a load to undo to get the engine out and one of the worst jobs is undoing the 19mm AF bolts at the top of the block to the gearbox. A long handled ring spanner is essential. Jiggling the engine forwards off the bellhousing spigots is easier if you have an adjustable engine leveller. I did not so had to do it manually
People vary when it comes to disconnecting the engine loom. I disconnect everything inside the cabin connected to the fuseboard, ECUs, O2 sensor etc and feed the whole loom through the bulkhead
Tight, but then the engine can go back complete instead of replacing the plenum in situ.
Engine out
And on the stand
Time to start stripping. Yuk
More later
The rebuild also gave me the excuse to prep the engine for the new development headers and the intention was to use an engine dyno to evaluate. For various reasons this did not happen and I have used a rear wheel dyno on the finished car instead. Development is ongoing ( I need to sharktune as the engine is now breathing so well the mixture is weak) but the headers are now fitted to two cars. That is another story but I have included a pic as a taster. Anyway they are making an extra 10 bhp and 10ftlb of torque before development so a good start
So. to the rebuild. I am lucky to have a 2 post an 4 post lift in the workshop which makes life much easier. 928 engine bays are packed and there is a load to undo to get the engine out and one of the worst jobs is undoing the 19mm AF bolts at the top of the block to the gearbox. A long handled ring spanner is essential. Jiggling the engine forwards off the bellhousing spigots is easier if you have an adjustable engine leveller. I did not so had to do it manually
People vary when it comes to disconnecting the engine loom. I disconnect everything inside the cabin connected to the fuseboard, ECUs, O2 sensor etc and feed the whole loom through the bulkhead
Tight, but then the engine can go back complete instead of replacing the plenum in situ.
Engine out
And on the stand
Time to start stripping. Yuk
More later