2.4T engine rebuild - Shock: It actually runs!

[Gary71]

Garage hours are limited this weekend so I'm not sure I'll get anywhere near timing. But maybe... I'd also have to drive back to work to get a DTI!

[Gary71]

Got further than expected! Starting to look more like an engine but still a long way to go with rockers, cam timing etc.

[Gary71]

One step forward...

Found a crack in a rocker shaft this afternoon, of course whilst fitting it...

So now I can't get them out again as the little RSR seals hold on really tight.

So the timing cases need to come off again so I can knock them back out.

New set of rockers on order, as I can't trust any of them, and some new gaskets to replace the ones I fitted yesterday!

[sladey]

Better to discover it now than when it breaks up at 6000 revs. Good save

[Gary71]

As usual it's been a while!

Some time passes and a new set of rocker shafts turn up and I'm now back to where I started, trying to time the cams.



Detail inspection of the shim that controls camshaft end float on the RH cam showed a groove was worn into it, so I've stopped again waiting for parts.



I've measured the clearance between the camshaft shoulder and the plate that fits on the end of the cam box and it all looks good, just need to replace the worn shim and it will be spot on.

I've stripped it all back down in readiness and thought that dry fitting the exhaust might be a good plan.



It almost fits, what to you expect for that much cash? Perfection? A small clash to the RH cambox will need relieving, and the locating tab appears to be upside down as it's lifting the exhaust up. It's a shame, but nothing that can't be overcome.




All this is setting the build back and it's so hard to determine what the next issue might be until you are actually ready to finally assemble it. As it's taken so long the MOT ran out today, so first drive will have to be to the MOT station which is far from ideal!

Plan is to get to Spa for the 24hr GT race at the end of July, but that is looking sketchy unless it all goes perfectly from now. Parts arrive from Porsche on Wednesday so back on it at the weekend, Fathers day will be a full 12hr garage session.

[bjmullan]

Keep the faith

[911hillclimber]

Doable.
Father's Day critical I think.

[sladey]

It almost fits, what to you expect for that much cash? Perfection? A small clash to the RH cambox will need relieving, and the locating tab appears to be upside down as it's lifting the exhaust up. It's a shame, but nothing that can't be overcome.



All this is setting the build back and it's so hard to determine what the next issue might be until you are actually ready to finally assemble it. As it's taken so long the MOT ran out today, so first drive will have to be to the MOT station which is far from ideal!

Plan is to get to Spa for the 24hr GT race at the end of July, but that is looking sketchy unless it all goes perfectly from now. Parts arrive from Porsche on Wednesday so back on it at the weekend, Fathers day will be a full 12hr garage session.

Hi Gary

If you decide to drill out that tab and reverse it with plug welds, I've got a reel of stainless MIG wire if you want to borrow it

Let me know

Cheers

Mark

[Gary71]

Thanks Mark but I'm planning to flatten it then rebend it, hopefully it won't crack!

[sladey]

Ok no problem - assumed you were drilling out and flipping round

[Gary71]

After some post based shenanigans eventually all the bits turned up from Porsche this morning.



...and a box of sundries from Beal:



But before that I took out the old oil tank.



...and tried to get the blanking plug out to fit to the new tank:



Increasing levels of violence and heat had no effect so I'll have to come back to that one.

I remade a few connections and wrapped the engine wiring loom, good breakdown prevention!



Then onto the cam timing and the first problem showed it's head:



I'm sure the chains are supposed to sit on the timing gear, not next to it. Arse.

An hour of swearing, manipulating with long pointy sticks and stretched fingers through the sump plate, but mainly swearing with escalating profanity levels, it was back on. My first thoughts turned to having to strip the whole engine again, so I wasn't best pleased.

First cam now done:



And stop for the night as I'm still completely wound up over the cam chains and need a beer!

[911hillclimber]

Cam chain side step happened to me when doing my Lola 3.2, absolute real nightmare.
I told Andrew not to let it happen!
Surprised more on here don't have the same issues, but not sure how many do actually DIY engine rebuilds anymore.

Cool beers and fresh start tomorrow.

[Gary71]

A largely productive day today. Cams timed, tensioners rebuilt, bled and fitted, oil lines on, oil cooler on. Rocker covers on, one exhaust on.



Then a minor set back.

This one definitely goes in the 'bloody annoying and expensive but thank God it happened' now category.

I cleaned up the big oil line that fits to the side of the case to fit it before the heat exchanger as access is virtually impossible otherwise.

As I wound it on, not even torquing it up, it snapped the nut under it's own weight!



If this fails on the road the consequences don't bear thinking about. So time for some new parts. For a change!

Still plenty to do with fan, carbs etc but it looks like an engine again!

[impmad2000]

Looking good Gary, great work in spite of some really aggravating setbacks !!

[AndrewSlater]

Looking good Gary - we all seem to hit a few different set-backs but hopefully get there in the end.

Probably a good thing the oil pipe broke during handling, as it wouldn't have lasted much longer on the car.

Starting to look like a proper engine now!