Turbo Engine Rebuild
- Thread starter scam75
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scam75
Well-known member
Thanks Thom.
250 miles down now, all good. Slight oil pressure reading issue, present before rebuild, documented on new thread if anyone can shed any light. Probably swap out the gauge and see how we go, although have been reluctant to do that as the battery reading is near spot on with current gauge (same gauge as oil pressure) and from memory the other gauge's battery reading is way lower than it should be. I'm sure you can calibrate this however by adjusting the resistor in the gauge and matching it up to your multi-meter volt reading which I done before to correct the current gauge. Probably worth swapping over though to see if the oil pressure issue goes away. Had a similar duff gauge issue before, temp gauge, it went the other way, through the roof for no apparent reason, then randomly managed to fix itself. Gauge swap out cured it. The beauty of analogue gauges.
Stuart
250 miles down now, all good. Slight oil pressure reading issue, present before rebuild, documented on new thread if anyone can shed any light. Probably swap out the gauge and see how we go, although have been reluctant to do that as the battery reading is near spot on with current gauge (same gauge as oil pressure) and from memory the other gauge's battery reading is way lower than it should be. I'm sure you can calibrate this however by adjusting the resistor in the gauge and matching it up to your multi-meter volt reading which I done before to correct the current gauge. Probably worth swapping over though to see if the oil pressure issue goes away. Had a similar duff gauge issue before, temp gauge, it went the other way, through the roof for no apparent reason, then randomly managed to fix itself. Gauge swap out cured it. The beauty of analogue gauges.
Stuart
scam75
Well-known member
Another thing I've noticed is slightly higher idle speed. Was bang on 850 rpm +/- 100rpm before rebuild, which I believe is correct. Now idling hot around 950 rpm (rock solid, no variation). Checked the TPS and it's set correctly for its click. Could be anything I suppose, but from memory when it idled at 850 rpm there was a buzz through the cabin from the semi-solid gearbox mount. This is gone at 950rpm so that's a good thing!
Observations are, that I have non-standard air metering, and with the wiring issue to MAF properly fixed my AFR's are different, better different, was very often too rich before, hot idle could be high 12's/low 13's. It's now about mid 14's hot idle and a lot less rich in the start up phase which is got to be a result of the wiring being fixed. Obviously haven't gone WOT yet in a big gear, but not seen anything below low 12's/occasional high 11's when asking for 10/11 psi in 5th. Also in cruise it is much leaner, 14's/15's when before it was 13's. So across the board the AFR's seem to be in a much better place. Maybe this accounts for the idle speed increase as well? I dare say nobody else is running a SciVision with my mods so this will reman somewhat a mystery, but a good, solid idle just under 1k revs is not something I will lose sleep over, just thought worth detailing as I continue to run in.
Other than these observations, the engine seems super strong and quiet. It's very quick in 5th, 70mph to 90mph even only deploying 8/9/10 psi, comes up very quick.
Also there is no evidence of any piston slap from cold (AMAC offset the pins to counter this). Fires up almost immediately and idles solid, no slap, no lifter noise. The 1.7KW starter is a revelation, it spins up very quick. So far, so good. Well worth the "journey" it took to get us here. Couldn't be happier.
Stuart
Observations are, that I have non-standard air metering, and with the wiring issue to MAF properly fixed my AFR's are different, better different, was very often too rich before, hot idle could be high 12's/low 13's. It's now about mid 14's hot idle and a lot less rich in the start up phase which is got to be a result of the wiring being fixed. Obviously haven't gone WOT yet in a big gear, but not seen anything below low 12's/occasional high 11's when asking for 10/11 psi in 5th. Also in cruise it is much leaner, 14's/15's when before it was 13's. So across the board the AFR's seem to be in a much better place. Maybe this accounts for the idle speed increase as well? I dare say nobody else is running a SciVision with my mods so this will reman somewhat a mystery, but a good, solid idle just under 1k revs is not something I will lose sleep over, just thought worth detailing as I continue to run in.
Other than these observations, the engine seems super strong and quiet. It's very quick in 5th, 70mph to 90mph even only deploying 8/9/10 psi, comes up very quick.
Also there is no evidence of any piston slap from cold (AMAC offset the pins to counter this). Fires up almost immediately and idles solid, no slap, no lifter noise. The 1.7KW starter is a revelation, it spins up very quick. So far, so good. Well worth the "journey" it took to get us here. Couldn't be happier.
Stuart
scam75
Well-known member
300 miles now, levels all good. Can also report a marked increase in MPG's which is pleasant. Something to do with not running too rich possibly, and also the engine not being knackered...........might clean the black soot from above the exhaust tip now I'm not topping it up every trip!!
Stuart
Stuart
scam75
Well-known member
Up to 450 miles now, still faultless, levels all good. Oil pressure gauge is behaving itself for the time being.
100 miles were done today out with my 10 year old son, for anyone that knows Scotland, up and over the Rest and be Thankful and other fantastic roads full of breathtaking scenery in that neck of the woods. What an absolute joy to drive. The boy now has a slight interest in classic cars which wasn't evident this morning!
In other news I've bought what looks like a really tidy centre air vent trim on ebay (I know, lovely pictures never lie!) for £35 delivered. I have two of them and both now have a broken vent flap hinge and had lost all the stuff that makes them seal anywhere near close to stop air coming through anyway. This other one still seems to have all the seals on it including what looks like felt at the rear. None of my two have got that. Hopefully it is decent and doesn't spit black foam at me when the vent is open!
Stuart
100 miles were done today out with my 10 year old son, for anyone that knows Scotland, up and over the Rest and be Thankful and other fantastic roads full of breathtaking scenery in that neck of the woods. What an absolute joy to drive. The boy now has a slight interest in classic cars which wasn't evident this morning!
In other news I've bought what looks like a really tidy centre air vent trim on ebay (I know, lovely pictures never lie!) for £35 delivered. I have two of them and both now have a broken vent flap hinge and had lost all the stuff that makes them seal anywhere near close to stop air coming through anyway. This other one still seems to have all the seals on it including what looks like felt at the rear. None of my two have got that. Hopefully it is decent and doesn't spit black foam at me when the vent is open!
Stuart
scam75
Well-known member
So that's us over the 500 miles now. Not a drop of oil or water lost. No noises of concern, oil still golden coloured, nothing coming out the exhaust, starter spinning fast and strong. Aluminium rad and converted turbo aux water pump all good, all road tests passed with aplomb.
Will be going to the garage on Monday for an oil change (Total Quartz Racing 10/50 fully synth) and full check over on the ramp. Need to add antifreeze, some new bobbins for my gearbox cooler and at long last I am going to fit the new (2nd hand but v good) fog lights to replace my cracked and chipped ones. A bulb is out too so will spend a bit of time and button it back up with stainless screws in the hope they can be removed easily in the future!
Stuart
Will be going to the garage on Monday for an oil change (Total Quartz Racing 10/50 fully synth) and full check over on the ramp. Need to add antifreeze, some new bobbins for my gearbox cooler and at long last I am going to fit the new (2nd hand but v good) fog lights to replace my cracked and chipped ones. A bulb is out too so will spend a bit of time and button it back up with stainless screws in the hope they can be removed easily in the future!
Stuart
] great stuff!
scam75
Well-known member
Thanks guys.
Went over to my air con mates house this evening. Pressure check, vac and re-gas. All good and thankfully my working AC system has survived the engine rebuild process! Icey cold air once again on tap although it was rather cold on the way home so the heaters were up full! When I pulled away we had near enough frozen the rear window when gassing up, however a few seconds on full demist mode sorted it out. Always been amazed just how good the 944 AC system is when it is working.
And it was dark on the way home. Dawned on me that I hadn't drove the 44 in the dark since being back on the road. Pop-ups up, quick light check, all good, hit the road home. Observations are that modern cars lights are way too bright and that I fondly remembered how pleasant the dimly lit cockpit is on a dark evening compared to modern vehicles. Another box ticked!
Also got to see his Mk2 RS Escort build in the flesh for the first time since completion. What a car. Built to rally spec with forest arches, 2 litre pinto with twin choke Weber 36's (was lumpy on 40's he said). Comes complete with model rally car mounted on the parcel shelf, of which his car in an exact replica. Horn and indicators are on the centre console, proper old school rally time machine!
Stuart
Went over to my air con mates house this evening. Pressure check, vac and re-gas. All good and thankfully my working AC system has survived the engine rebuild process! Icey cold air once again on tap although it was rather cold on the way home so the heaters were up full! When I pulled away we had near enough frozen the rear window when gassing up, however a few seconds on full demist mode sorted it out. Always been amazed just how good the 944 AC system is when it is working.
And it was dark on the way home. Dawned on me that I hadn't drove the 44 in the dark since being back on the road. Pop-ups up, quick light check, all good, hit the road home. Observations are that modern cars lights are way too bright and that I fondly remembered how pleasant the dimly lit cockpit is on a dark evening compared to modern vehicles. Another box ticked!
Also got to see his Mk2 RS Escort build in the flesh for the first time since completion. What a car. Built to rally spec with forest arches, 2 litre pinto with twin choke Weber 36's (was lumpy on 40's he said). Comes complete with model rally car mounted on the parcel shelf, of which his car in an exact replica. Horn and indicators are on the centre console, proper old school rally time machine!
Stuart
scam75
Well-known member
Just back from the garage. Oil change done, 600 miles covered in running in period. No oil lost and removed oil inspection passed with flying colours. Now got a fill of Total Quartz Racing 10/50 fully synth.
Removed the water from the cooling system and this was nice and clear and now refilled with antifreeze mix.
Full check over and inspection showed no issues with undertrays removed. Very minor sweat at front crank seal which we will monitor. Hopefully be ok now with thicker oil in it.
Last job today was to swap out the very cracked NS fog light unit, which crumbled on removal. I've had for a while 2 decent uncracked glass units, but not the rear casings. Both main bulbs were also out. Upon refitting we had side light and full beam, but no fog light. Did some testing but no power getting to the bulb. Was working before engine rebuild. Anyway we were able to get in behind and give the loom a wiggle and then left it at that as it cooled down before we topped up the levels. Checked lights when leaving garage, all working! How we laughed!
I could definitely be doing with a pair of plastic rear casings however as currently we only have one properly secured screw at one end of the NS unit and a couple of self-tapping bolts securing the other end. Certainly not going to move or fall out but be nice to find a couple of casings somewhere. I'm sure Porsche only supply the full glass units complete with the rear casings for silly money IIRC. At least all my bulbs work now and the glass isn't cracked! Let me know if anyone can help with the bits I need although I'm sure they fall into the rocking horse poo department.
Stuart
Removed the water from the cooling system and this was nice and clear and now refilled with antifreeze mix.
Full check over and inspection showed no issues with undertrays removed. Very minor sweat at front crank seal which we will monitor. Hopefully be ok now with thicker oil in it.
Last job today was to swap out the very cracked NS fog light unit, which crumbled on removal. I've had for a while 2 decent uncracked glass units, but not the rear casings. Both main bulbs were also out. Upon refitting we had side light and full beam, but no fog light. Did some testing but no power getting to the bulb. Was working before engine rebuild. Anyway we were able to get in behind and give the loom a wiggle and then left it at that as it cooled down before we topped up the levels. Checked lights when leaving garage, all working! How we laughed!
I could definitely be doing with a pair of plastic rear casings however as currently we only have one properly secured screw at one end of the NS unit and a couple of self-tapping bolts securing the other end. Certainly not going to move or fall out but be nice to find a couple of casings somewhere. I'm sure Porsche only supply the full glass units complete with the rear casings for silly money IIRC. At least all my bulbs work now and the glass isn't cracked! Let me know if anyone can help with the bits I need although I'm sure they fall into the rocking horse poo department.
Stuart
scam75
Well-known member
Another couple of hundred miles now since the oil change. Still not bouncing it off the red line just yet!
Ceiling set about 5k revs now and allowing the odd burst of 15/16 psi boost. I can confirm it doesn't hang about!
As always there are things to attend to away from the engine. Some bits of paint and a couple of paint bubbles to deal with. Going back to place that done the sills on 1st November to have the work done.
Stuart
Ceiling set about 5k revs now and allowing the odd burst of 15/16 psi boost. I can confirm it doesn't hang about!
As always there are things to attend to away from the engine. Some bits of paint and a couple of paint bubbles to deal with. Going back to place that done the sills on 1st November to have the work done.
Stuart
scam75
Well-known member
blade7 said:
Sorry about that! All is well, done about 800 miles now in total. Not lost a drop of oil or water. Creeping a bit closer to the red line now and then and all good.
Dropping it into the paint shop today for a few bits and pieces to be tidied up. Should have it back next week at the latest.
Stuart
scam75
Well-known member
Afternoon guys.
Picked the car up from the paint shop yesterday, very nice work I have to say and all looking good.
The car hadn't ran for 2 weeks, so it needed a jump. Started no bother and had it running for ages before I left and seemed to air lock a bit and temp climbed up to nearly 3/4 on the gauge. Anyway, it settled down on the drive home and I left it overnight. Was at min (been sat at max previously for weeks) and needed a litre of water this morning to return it to max level, topped up and all seems ok. Oil perfect.
Need to keep an eye on it, possibly had some air in the system previously which has made its way out now? Time will tell.
Stuart
Picked the car up from the paint shop yesterday, very nice work I have to say and all looking good.
The car hadn't ran for 2 weeks, so it needed a jump. Started no bother and had it running for ages before I left and seemed to air lock a bit and temp climbed up to nearly 3/4 on the gauge. Anyway, it settled down on the drive home and I left it overnight. Was at min (been sat at max previously for weeks) and needed a litre of water this morning to return it to max level, topped up and all seems ok. Oil perfect.
Need to keep an eye on it, possibly had some air in the system previously which has made its way out now? Time will tell.
Stuart
scam75
Well-known member
No water missing this morning. Still sitting at max. Ran it up to temp whilst attending to tyre pressures and all was good. Can't see any leaks anywhere although admittedly only looking in from the top. Will check it daily to see if any more water goes walk about, hopefully not.
Going to see my friend on Saturday to get a new set of stone guards and a rear PORSCHE decal fitted. Also dropping him my acquired front CS rim (which is nice and round), to be powder coated the same as the wheels on the car. I will then be able to swap that over for my front rim that has a dink in it which causes a slight wobble between 60 and 70 mph. Although to be fair, it is minimal especially since I discovered "Road Force" wheel balancing which made the issue 95% less than previous.
Stuart
Going to see my friend on Saturday to get a new set of stone guards and a rear PORSCHE decal fitted. Also dropping him my acquired front CS rim (which is nice and round), to be powder coated the same as the wheels on the car. I will then be able to swap that over for my front rim that has a dink in it which causes a slight wobble between 60 and 70 mph. Although to be fair, it is minimal especially since I discovered "Road Force" wheel balancing which made the issue 95% less than previous.
Stuart
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