Turbo engine replacement

[tref]

Any one have a spare Turbo engine they don't want lying around?

Also, any advice with regards to removing/replacing? The Haynes book of lies says move gearbox/torque tube back... I'm surprised at this given it isn't necessary on a 944 (veteran of many a 944 engine swap!) and there seems to be a lot more room around the 2.0litre lump. I assume the cross member still needs to be lowered to allow the sump forwards/clutch housing prevents a straight lift.

If one were to remove the head in situ first, where is it best to separate the Turbo/exhaust manifold assembly?

What online 924 technical resources are there?

Any advice gratefully received!

Best regards,

Tref.

 

[924nutter]

You definitely do not want to go down the gearbox out route. I am hoping that this month's 'Post may carry my article about gearbox removal on the turbo, but they might give someone else a chance.
Re head: see September or October issue 2004 Porsche post, if not email me, I still have the article on cd rom.
A few pointers. Undo the four bolts from the front of the torque tube.
Make up a wooden cradle that fits around the front and rear wheels. Mark the front suspension bolt positions.
Drop the front suspension; the cradle will allow quite precise repsitioning of the front cross-member.
Remove the oil coler pipes to undo the turbo at the manifold flange (3) bolts. Plus all the other obvious bits like the radiator and so forth.
Engine should pull forward and then up. I have done the 924 n/a like this but I did it the hard way, way back when, and proceded to undo all the bell housing bolts leaving that attached to the torque tube. Ahh the learning curve!

 

[tref]

Thanks, just the type of information I'm looking for...

The gearbox on the 944 was the easiest I have ever had the displeasure of removing; none-the-less, glad to hear I don't have to remove it! Disconnecting torque tube to bell housing is how I have approached a 944 engine out in the past, though on that it comes down and out (much prefer the idea of up and out, I have an engine crane, but not a lift).

"Make up a wooden cradle that fits around the front and rear wheels" Wow, thats a big cradle! I presume to ensure suspension settings go back as they were? My immediate thoughts are a piece of batten with a couple of metal plates that bolt onto the wheel studs - is this adequate?

Thanks,

Tref.

 

[tref]

As I now have a healthy engine I need to remove in one piece, can anyone confirm that I can still remove up and out, by seperating the torque tube from the bell housing, and lowering the crossmember? Still no need to move the gearbox?

Presumably leave the turbo/wastegate/exhaust manifold in place on the engine...

Tref.

 

[924nutter]

That is definitely the way it comes out of a 924. The turbo does have the 'blower hanging down but I don't think it is any further forward than the bottom pulley and no lower than the sump. You will need to locate the clutch pipe support brackets one is obvious the other is secured to one of the distibutor drive housing bolts. Get a nut splitter to remove the four nuts from the pipe connection below the wastegate, and undo the two from the other end of the pipe; leave the wastegate on the vehicle. With the cross member dropped the rack will be out of the way allowing the 'cooler pipe banjos to be taken from the oil thermostat housing which will let you access the bottom turbo flange bolt. If you paint all around the cross member position with tippex you ought to be able to reposition fairly accurately.

 

[tref]

Engine is now out...

Crossmember dropped, together with rack, anti-roll bar, and it was necessary to drop the steering column shaft from the rack in the end as well. I took the wastegate right off. I did indeed mark the crossmember with tipex, as with the rear wishbone mountings, but I also have the advice of a chap with a very sweet handling 924S who set up his own suspension, so not too worried about losing the correct settings.

Torque tube/gearbox stayed exactly where it was, just in case there was any doubt.

As this engine is pretty much scrap (I will open it up and have a look at some stage), I also removed things like the waterpump and left-hand engine mount bracket, inlet manifold, just to give me some more room.

It then lifted out very easily.

The donor car may be a different story!

Regards,

Tref.