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944 Turbo S Engine Rebuild Thread

Eldavo said:
Roger, how many times are we going to keep going round in circles? You are a laughing stock on every forum you’ve besmirched and on FB too. I got a message just this week about how you’d offered somebody who doesn’t even own a 944 an unsolicited copy of your "£30k build spreadsheet”.
I’d rather you didn’t comment on this thread again please. I wish you all the best with your build and your racing career, may it be long, relatively uneventful, and ultimately keep you busy.
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What's wrong with that (A 30k buildsheet) ?

What Build? that was 6 years go mate, all done just the once.......!!

Keep your wig on, and calm down![:D]

R

 
PSH said:
Well done David, happy days ahead...not sure what your specific ring bed-in procedure is? but what Roger said is sound advice. You need heavy load, on and off the throttle and keep below 4k rpm. No long motorway driving at constant speeds for a few thousand miles at least. Change the oil within 1k miles, IIRC I changed mine at 500 miles and changed again before going to fully sythetic later.. can't remember how much later but I would guess it's in my build log.

have fun and enjoy...:)

Pete
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Thanks Pete, got some specifics around maximising cylinder pressure for 10 or so cycles and will then take the engine builder’s route up to the Scottish Border on the country roads, rev limit has already been set to 4K. I’m running Miller’s CRO running in oil, when I get back that will be changed. Then some more running around before a change for the summer and hopefully a track day or two.
 
As I was back at work today I had to pay somebody else to drive my car [:D]

Upshot is that the cylinder rings are now broken in, car is sat on the ramp while the oil drains out overnight - then a fresh filter and fill before it‘s off for MOT. Will run it in for another 500+ miles when Boris allows before another oil change for the good stuff and then upping the boost/rev limit. A slight coolant leak from one of the hoses was found and remedied by a new jubilee clip - given the myriad of cooling hoses on the Twbo I’m surprised it was only 1!!!

Back into the body shop on the 1st of March for a couple of bits that got missed/I wasn’t totally happy with.
 
We may have crossed swords a few times, but I know a good engine thread when I see one !

Well done .. [:D]

cheers, Maurice
 
MoC2S said:
We may have crossed swords a few times, but I know a good engine thread when I see one !

Well done .. [:D]

cheers, Maurice
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Thank you Maurice, I appreciate the sentiment. It’s important to remember the things that bind us together despite the airtime given to those things that try to drive division between us.
 
Eldavo said:
MoC2S said:
We may have crossed swords a few times, but I know a good engine thread when I see one !
Well done .. [:D]
cheers, Maurice
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Thank you Maurice, I appreciate the sentiment.

It’s important to remember the things that bind us together despite the airtime given to those things that try to drive division between us.
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You been sniffing Petrol again ? :ROFLMAO:

R
 
And hello !! to Diver as well .. I see you've stayed the course even if you're in Ambleside !

cheers, Maurice
 
Got my 12 month ticket, just need to sort out getting it back from the garage once The alignment and last few jobs have been done [s1]
 
I was just finishing off my last Zoom meeting of the day on Friday when a very distinctive noise heralded the delivery of my car back where it belongs.
 
Gave it a much needed wash and hoover out - and fitted these 3D printed dash vent inserts a mate did for me. Finishing touch after I skinned the dash in red stitched black leather a few years back.


I also ran the cabling through the firewall and into position for fitting my Wasted Spark setup n
 
Cracking on with the wasted spark setup, I removed the distributor, HT leads, coil, rotor arm, cam extension and front cam cover.

Bolted a couple of rubber standoffs on (they’re part of the airbox assembly on A 996/997 that my Indy’s ordered in for me) and bolted the coil to a 3mm anodised sheet of aluminium I cut to shape with an angle grinder and CAD model - (Cardboard Aided Design) [;)]
 
Then just a case of putting it back on along with the top belt cover, running the modified Magnecor KV85 HT leads, repinning the ECU connector and connecting up the ignition switched 12v wire from the original coil to the new coilpack.

A quick tinker with the laptop settings for the new outputs and the coilpack dwell time from the data sheet and ready to roll - once I tax it and we’re allowed!

Put the strut brace back on too - save me tripping over it in the garage.
 
Haha - cheers Colin.


My special extending ladders shouldn't even be on that wall. That’s where my QuickJack lift lives but it’s been on holiday in a YouTuber’s unit for the past 6 months or so.
 
Yes ,I was very tempted to buy a Quickjack,last time I was in Costco,but thought better of it.
Wasted spark ignition:-having seen references to it on various occasions & seeing your posts,I read up up about it & got the impression that one would not necessarily get much advantage from using it on a 4 pot engine,but that was only gleaned from Google topics which although supposedly technical didn't explain the topic very well & was motorcycle engine biased.
With your advanced engine work & obvious knowledge ,it must give you some advantage -have you more info you could share ,David?
Colin.
 
Sure Colin, the ideal would be wiring in a cam sync sensor from Clewett or the like and moving to fully sequential ignition with COP packs. It’s doable but the space isn‘t suited for COP and some of the solutions for holding them in position are a little inelegant if anything.

Wasted Spark seemed a good halfway house to get rid of the old coil and distributor setup whilst providing a stronger spark at higher boost levels. I have had issues in the past where I’ve had spark blowout at 18psi boost and had to knock it back to 15psi, given that (post running in) I’m probably going to run around 21psi boost it seemed a cost-effective no brainer to do it now.
 
Did some running in yesterday with a mate and his practical recovery vehicle for "just in case”. I had VEMS running autotune on the laptop, the car was noticeably smoother on the way back after I’d burned the tuned map to the ECU. Had a couple of Overboost issues as I’d knocked the boost target back to 18psi, put an Overboost fuel cut at 19.7psi but left the solenoid duty table setup for 23psi - doh. Just had to not floor it, probably not such a bad thing when running it in still.


Apart from that, all was well - I forgot just how planted it feels and how communicative the chassis and suspension are. I also forgot that with no sound deadening under the carpets, when a stone hits the underside of the car - just how scarily loud it is. Given the laptop on the passenger side, it felt a bit Paul Walker "danger to manifold” and I worried about my floor pan blowing out!
 
I'm not entirely sure the practical recovery vehicle was described correctly [8D] How many miles on the runing in so far?
 
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