Engine build progress
- Thread starter TTM
- Start date
TTM
Active member
Fitting the remaining hardware (exhaust, alternator, power steering, intake, etc) should take about 1.5 day. As I'm ditching the A/C we should have plenty of room for the intake. Doing the electrical part though is a long and tedious job that will certainly require a complete weekend. In any case I will have a week or two of free time by the beginning of August, so it would be great to have her ready by then so I can take all the time I want to run it in. There are other things that would be worth doing while the car is on stands though, such as fitting the JRZ rear shocks that have been waiting since I bought the car (we would have to reindex torsion bars, which means another weekend of work) and have fellow marcoturbo show me his talents in fighting rusty spots 
marcoturbo
New member
Luckily, there are many Bilt Hamber products at Sly's !ORIGINAL: TTM have fellow marcoturbo show me his talents in fighting rusty spots
TTM
Active member
Here are some pictures from two weeks ago. Lightened flywheel, was balanced with new pressure plate :
Additional soldering on the flanges of exhaust manifolds :
Machining off the edges caused by the original soldering :
Wrapped manifolds :
Blank-fitting the X-over pipe to check for adjustment.
Heating the X-over pipe to relieve excessive strain noticed when fitting :
It looks good when it's all shiny ; I noticed when ordering the oil line for the oil cooler that there was two part numbers and ordered the one for a '90 turbo (my car) without knowing what the difference with the other one would be, and eventually noticed when fitting the oil line that the oil filter housing we used, coming from an early '86 turbo, did not feature any hole where the bracket on the oil line could be attached - that may explain the difference between the two different parts :
Just looking good :
Fitting pressure plate in order to adjust sensors :
Adjusting sensors :
Machining the clutch bellhousing so the sensors bracket can stay on the engine when lowering it into the engine bay :
930 clutch disc :
Almost there :
Getting ready for engine reception :
Here we are at last [] :
More progress tomorrow.
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TTM
Active member
I fitted the black unit, which is still available from Porsche and comes drilled. The white unit, also available from Porsche and the only one sold by most aftermarket parts suppliers isn't. Following SimonP's recommendations the turbo cooling system will be slightly different than stock.
Thanks for the kind comment. The picture showing the bare block being washed outside was taken at the end of last summer, but my car was still running its original 2.5 engine until we took it out a couple of months ago.
sawood12
New member
Great thread Thom, keep it coming. Looking forward to seeing it completed. Photos are good as well. It helps those of us who don't tend to get our hands too dirty visualise what the engine looks like. A couple of questions though if that's OK. Love the black cam tower with polished Porsche script. Is that powder coated or painted? Your comments to Nick 968 RE waterpump - I'm looking at a timing belt replacement later this year and will refresh my waterpump. Are you saying the for the turbo you can only get the proper pukka waterpump from Porsche and if you get an aftermarket supplied pump you need to modify the pump? Also your flywheel - how much is it lightened? Looking forward to the next gripping instalment! Cheers. Thanks.
TTM
Active member
Hi Scott, thanks again for the encouragement! I think the cam tower was only painted - this is how it was when I got it - and I think I will be lucky if the paint holds against the heat, but I'm pretty sure it won't [8|] Taking it off later to install a Milledge camshaft will be a good reason to have it properly powder coated [] I am refering to the plastic elbow held onto the front of the water pump by two bolts (I think this is what Nick is talking about?), not the water pump itself. Can't remember how much material got shaved from the flywheel, think it was about 1.2kg or something but will ask Sly if he remembers.
] I am refering to the plastic elbow held onto the front of the water pump by two bolts (I think this is what Nick is talking about?), not the water pump itself. Can't remember how much material got shaved from the flywheel, think it was about 1.2kg or something but will ask Sly if he remembers.
TTM
Active member
Alternator, PS pump and fans are back on, the coolant loop is done. Remains the intake, exhaust and modifying the wiring loom. Fellow Marc stopped by and was kind enough to clean the wheel arches and the battery area. Was easier to fit back the hood with a third operator too. Because of the shape of the coolant passage between the head and the block, that is located slightly further up front compared with a 2.5 engine, the connector to the thermoprobe was modified slightly as it would touch the coolant duct going from the head to the radiator. I also suspect the airbox will have to be slightly cut off to clear the head. Also have to order a specific '86 exhaust clip as we will be fitting a complete '86 exhaust line that has a bigger inner section than the '90 unit that came off my car - in a similar fashion to the downpipe mentioned previously - and it won't work with the later style flanges on the exhaust line of the wastegate tube. There is good chance that next time I will be posting in this thread at the beginning of August the engine will have either been correctly started or thrown its internals around in the engine bay []
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