944 Turbo S Engine Rebuild Thread
- Thread starter Eldavo
- Start date
Got the replacement Continental cam belt from Justin today and fitted it instead of the QH one.
Don’t know why really but gave me something to do!
Installed the rear bearing bridge, the 3 plastic disc seals and then cracked out the Reinsosil for the cam cover:
With that on and the heat shields under the manifolds I’m pretty much there. A couple of hoses to sort and I’ll remove the aircon compressor for packaging reasons - car is booked in for the engine being physically put back in along with the flywheel, clutch, bell housing, etc. in 2 weeks. I’ll get it recovered home and do all the wiring and plumbing then.
But until then, time to tidy the tools up and start working out how to wire the COP loom in:
Don’t know why really but gave me something to do!
Installed the rear bearing bridge, the 3 plastic disc seals and then cracked out the Reinsosil for the cam cover:
With that on and the heat shields under the manifolds I’m pretty much there. A couple of hoses to sort and I’ll remove the aircon compressor for packaging reasons - car is booked in for the engine being physically put back in along with the flywheel, clutch, bell housing, etc. in 2 weeks. I’ll get it recovered home and do all the wiring and plumbing then.
But until then, time to tidy the tools up and start working out how to wire the COP loom in:
You’re kidding right? Absolutely bricking it!
I’ve got the wiring loom laid out for COP for when it goes back in - engine is being physically put back in in 3 days time!
I’d given some thought to the distributor cover and nobody seems to make a suitable one for the 16v engines so a mate popped by to take some measurements and then 3D printed me this from ABS so good up to about 260°C:
I’d given some thought to the distributor cover and nobody seems to make a suitable one for the 16v engines so a mate popped by to take some measurements and then 3D printed me this from ABS so good up to about 260°C:
Put the engine stand and the platform together and then raise the bed to connect up the engine mounts:
Remove engine stand, fit flywheel and . . .
Find out that the EPS 930 clutch disc from D911 (you know the one that clearly states is a direct fit for the 944T on the EPS website) doesn’t fit and the splined section is 4mm greater diameter than the release bearing
.
Remove engine stand, fit flywheel and . . .
Find out that the EPS 930 clutch disc from D911 (you know the one that clearly states is a direct fit for the 944T on the EPS website) doesn’t fit and the splined section is 4mm greater diameter than the release bearing
.
So, ordered a replacement Sachs disc from FVD Brombacher in Germany - highly recommended, phoned them up to query lead time on the part, they rang the Sachs warehouse, got a confirmation email from them that the part was in stock and it would be despatched within 2 business days, then forwarded me the email with a UPS express quote too . . . all within 10mins of hanging up the phone!
The Sachs one has a much thinner walled splined area - and is (fingers crossed) an actual direct fit.
So, in order to make the car mobile again to push it out of the workshop we put the engine in:
And we can just drop it down again when the clutch arrives:
The Sachs one has a much thinner walled splined area - and is (fingers crossed) an actual direct fit.
So, in order to make the car mobile again to push it out of the workshop we put the engine in:
And we can just drop it down again when the clutch arrives:
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Got the replacement clutch disc fitted - also spoke to Simon who’d fitted the EPS one and then said “oh yeah, we had to machine the end down 4mm on a lathe to make it fit” 
Never let it be said that lining a 944 engine up with the spline from the torque tube is easy though:
But before long it was back in, with a new slave cylinder then fitted for good measure:
Fast forward a day or so and the recovery driver made an inch-perfect delivery. In his own words “I’ve had enough practice with this car though haven’t I?” Cheeky git but he’s not wrong!
Never let it be said that lining a 944 engine up with the spline from the torque tube is easy though:
But before long it was back in, with a new slave cylinder then fitted for good measure:
Fast forward a day or so and the recovery driver made an inch-perfect delivery. In his own words “I’ve had enough practice with this car though haven’t I?” Cheeky git but he’s not wrong!
With the wiring loom installed and the alternator in place it was time to start working out where the loom would go for the COP setup.
So, hopefully the last time I see these pistons for quite some time:
And the trimmed down Lamborghini Hurracan (and Golf GTi) coilpacks fit in perfectly on a 16v head and look really smart:
So, hopefully the last time I see these pistons for quite some time:
And the trimmed down Lamborghini Hurracan (and Golf GTi) coilpacks fit in perfectly on a 16v head and look really smart:
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