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Another 944 Turbo Engine Rebuild Thread

Helloooo,It’s on about 80k I think?
It’s not used every year and some years it does very few even when it’s on the road,but it runs really well,been to Europe in it a few times over the years for track days and to Cornwall.It had a full examination when it was put together,and a “new” big valve head ,I need a new cone filter at some point looks a bit old now but that can wait till next year,the black one is coming out Friday and I’m looking forward to that
 
What's the spec on the black turbo? Changing the subject I recently took my turbo out for the first time this year. It was running a bit low on boost, and after resetting it, I was surprised how well it goes now.
 
Pretty Standardish ,Promax Chip,Boost enhancer,intercooler upgrade,M030 suspension,968CSarbs,Castor mounts,strut brace,New Blaupunkt Bremen!First bought this in 93 👀 👴🏻
 
KW's plus the usual bits and pieces people fitted years ago. I bought a brand new LR 61-10 from Promax around 10 years ago, but I've never got around to fitting it. I don't use it enough, but that means it feels a bit special when I do.
 

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I’ve got a set of forged wheels powder coated in black that would look amazing on the blue car!
Was the blue car a Turbo S originally, quick restoration then up in a fancy showroom for loads of money. Never raced or rally'd :D
 
Got a set of gloss black CS ,they do feel lighter,the black car is a bit of a nostalgia car ,bought it first time in early 20s,it came with the D90s…trying to relive youth now 👀😂
 
Whilst the cats away! Talk about thread takeover :ROFLMAO:

Back from holiday now, hopefully I will have some time to start working on the car. Still got a sore throat though following a nasty bug I picked up.

These pictures are from the week before I went away where I made some progress.

Close up of the corrosion on the cross member beneath the intercooler, and the patches of corrosion from friction between the coolant tank and the wheel arch.





On removing said corrosion, there were a couple of spots where I could poke a hole with a screwdriver... luckily the majority of the section was in good condition. I cut out the worst spots with a Dremel, if I had a welder and the skills I would have patched them, but it is hidden and shouldn't reduce the structural integrity.







Used a good zinc-based primer to prepare for the colour coat.





Then a coat of colour, and some clear coat on the wheel arch (didn't bother with any clear coat on the cross member).







Then I fitted the new heater hoses, and a new engine earth cable.

 
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I spent more time cleaning the intercooler exterior, lots of banging on the floor to loosen debris stuck in the fins, followed by vacuuming. Then I soaked the fins with degreaser and used the garden hose (to avoid damaging the fins with high pressure from the pressure washer) to flush. Then after it had dried inside next to the radiator, more banging on the floor to loosen debris stuck in the fins. Finally refitted with new/cleaned hardware!









My new clutch master, and slave cylinders arrived, and I dug out my new power steering reservoir which was a steal at £15 from an ebay seller.



Vapour blasted cross member and air conditioning hoses picked up from my friend Matt at MB Engineering.





I then started a job I'd been putting off, cleaning the power steering rack. It cleaned up very well with plenty of brake cleaner to start, then some water based degreaser and the pressure washer. Unfortunately, the hard lines are heavily corroded but will see how I get on when it is re-fitted.









With the intercooler reinstalled, it was time to refit the badge panel.



 
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