2.4T engine rebuild - Shock: It actually runs!

[Gary71]

It's been quiet for a while but I've started to progress things now. I'm taking various bits of engine for the following jobs:

- Beadblast & prep heads
- Replace valve guides
- Recut seats
- Reface head sealing surfaces
- Line hone crankcase
- Remove bent head stud
- Polish and clean crank

I've also ordered the following little list from Rose Passion which covers most of the parts I need. A few more to go from Type911 (oil returns etc) but this should keep me going for now!




Also arriving is a new oil tank and rear jacking point adaptor from Marek via Carpoint on Ebay.

So hopefully sometime towards the end of March it can all start going back together...

[911hillclimber]

Why the cylinder head nuts?
Some of those prices are very good in my recent experience.

[Gary71]

A bit of a luxury really, a few were looking a little wounded in the hex so bought new rather than risk rounding something. I didn't buy new washers though

Those prices are each so they do add up, particularly those valves!

[911hillclimber]

Yep, remember buying the set of Ex for the Lola's 3.2...

[bjmullan]

A very good price on the exhaust value. Keep up the good progress, you will beat me by years!

[Gary71]

So here it is:



Doesn't look like a family holiday's worth of bits does it?

Such is the joy of Porsche ownership, it if were a Golf it would be £500 all in!

[Gary71]

I picked up the case/heads/crank from the machine shop this morning after a long and very wet early drive down. Shockingly it was on time, on budget and certainly by visual inspection so far appears to be to quality... Maybe miracles do happen?

Heads - All shiny ready to be rebuilt
Ported, bead blasted, new valve guides, recut seats, refaced gasket surface, and finally thread inserts for the exhaust studs replacing my dodgy efforts with helicoils, some of which have been done from underneath the car with a hand drill!





The next job is a dry build of crank into case with the new bearings and make sure it turns over.
I'm going to borrow some decent scales from work this weekend and check the pistons/rod balance and make any adjustments before the detail cleaning and rebuild proper can start.

A boat may have been more appropriate transport at times this morning! I turned around at this point...

[210bhp]

Hi Gary

Did you have the crank and rods magnaflux tested?

Regards
Mike

[Gary71]

Hi Mike, No, but I can do that here if really needed. My view is that in the low reving power free environment of those slab sided T's it''s unlikely to be a concern.

Despite that comment if there was a concern I think it would have revealed itself by now with my driving style

What's your view?

[210bhp]

I'm not sure, that why I'm asking. It's something that's hardly ever mentioned in rebuild threads whether they be 'home' or 'specialist' done. Plenty about balancing of weight, bench flow testing, honing, line boring etc but no real mention of checking the well being of the crank ( and rods).

I am asking from the point of view that my Range Rover Sport crank has just split in two after 49k miles and I know I am not a hooligan driver like you so I was just looking out for you. After all, you don't want to spend the price of a two months holiday in New Zealand on your engine only to find the crank cracked and/or bent after just 49k miles (and 3 months out of warranty). That would make a grown man cry.

Regards
Mike

[Gary71]

Sorry to hear about the RRS, will send you a pm on that subject.

[majordad]

Where did you get the oil tank, I need one for my 2.4 S, and how much please ?

[Gary71]

Hi it's from Tangerine911 on eBay, about £400 posted. Half what you can pay from Porsche for what is these days exactly the same part!

[hot66]

I'm not sure, that why I'm asking. It's something that's hardly ever mentioned in rebuild threads whether they be 'home' or 'specialist' done. Plenty about balancing of weight, bench flow testing, honing, line boring etc but no real mention of checking the well being of the crank ( and rods).

I am asking from the point of view that my Range Rover Sport crank has just split in two after 49k miles and I know I am not a hooligan driver like you so I was just looking out for you. After all, you don't want to spend the price of a two months holiday in New Zealand on your engine only to find the crank cracked and/or bent after just 49k miles (and 3 months out of warranty). That would make a grown man cry.

Regards
Mike

ouch ! TDV8 or was it a 6 ? Reason i got rid of my Range Rover was it neaded quite a bit of warrenty work in in the 8 months I had it & mine was a good one too ( and it was depreciating like a stone)

[210bhp]

Sorry to hear about the RRS, will send you a pm on that subject.

Thanks Gary,

Replied.

Regards
Mike