eldavo69

944 Turbo S - Project Time

746 posts in this topic

3 hours ago, eldavo69 said:

4 seats (ish)!

If that's what I think it is, the emphasis is very much on the "-ish".  Unless your passengers are OK about having their legs sawn off just above the knee :blink:

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Shhhh . . . . How do you think I’m justifying a 5th car to my wife!

Although the Boxster is probably going to get sold in March/April but every time I mention it, the Mrs goes and drives it again and falls for it anew. 

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The 944 Twbo S is finished - sort of. It needs a seam in the exhaust welding back up but the garage that made the exhaust can’t fit it in until the beginning of next month. I’m reticent to bring the car home as it’s currently 1/2 a mile from the exhaust place so hopefully they’ll see sense. It’s running really rich when warm, I’ve checked the logs on the laptop and I think the ECU engine temperature sensor is duff - I have a new one to get fitted this week so hopefully that’s that sorted. 

 

Ive not driven the Twbo since I dropped it off at the garage in September. Since October I’ve driven the Boxster for about 1 week when I used it as my daily driver - it’s sat in the dehumidified garage polished and preened on a battery charger.

Given that the Twbo will be going back in the garage (and the other half is now a gym) it means that the Boxster will be sat outside on the drive. Therefore, after a lot of soul searching I’ve decided to do the sensible thing . . . . . I’ve bought a 911 to keep it company. 

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21 hours ago, eldavo69 said:

The 944 Twbo S is finished

:roflmao::roflmao::roflmao:

Like any of us are going to believe that? :P

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Nearly finished me off!

 

(alright, I have a new coolant tank and all the coolant hoses to replace, an oil leak to fix, dyno and road tuning to do, my new seats should be here next week, the rear hatch still needs tinting and the running problem needs sorting - a weekend’s work tops*)

 

*assuming I get a completely free weekend at some point ever. 

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We expect piccies of the completed beast.  :)

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Don’t worry, there will be!

Theres a link to the progress album on Facebook on the previous page too. 

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If you think you've finished, just take it to Blyton Park and something will break for you +++

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Back in November I spent some time at GSM Sport Seats trying out a load of buckets to find some that were a perfect fit. 

Ordered them in late January and they finally turned up last week in a rather large box. Picture is of the larger passenger seat, mine is still in the box - same style but one size smaller.

 

 

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Wings have been massaged into place, the brackets needed a bit of fettling to line up. 

Just a bit of paintwork on the rear quarter to be redone and then it’s coming back to mine!

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I got the car back a couple of weeks ago and it’s been busy busy since then. A few snagging jobs that it’ll have to go back to the body shop for but until then the main focus was in getting it started. 

Starter motor was making a horrible noise and turning over slowly so I removed that - it’s at the very bottom and back of the engine, an easy job of it wasn’t for all the heatshields in the way. Took it to the guy who refurbed my alternator, he stripped it down re-lubed it and reassembled it for no charge. It’s running faster and quieter now, the horrible noise was a copper washer I had dropped down the back of the flywheel when doing the reference sensor gaps and it was just bouncing around a bit - oops!

Chucked some new spark plugs in and it fired into life, although still super rich (AFR around 10 for those who understand such stuff). It’s been said that these cars and engines don’t like being stood around a while, I guess that’s true as oil was dripping from the cam gasket seal onto the exhaust manifolds and billowing white smoke. 

Fuel rail off, distributor off, timing belt covers and timing belt off, then remove cam tower trying not to drop the hydraulic lifters everywhere - a couple of hours later and it looked like this:

 

 

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Got some new shiny shiny bits to fit too, a new expansion header tank that I bought myself for Xmas (£200!!!) and a set of silicon radiator hoses to replace all the crusty old perished rubber ones:

 

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I’d noticed a slight blow from the exhaust manifold too, with the cam tower off access to the manifolds was “easier”. I say that as you have to double-nut the studs and remove them from the head as there isn’t enough room to get the manifolds off in situ. If s stud breaks then you have to remove the cylinder head and get s machine shop to get it out due to the lack of access. 

Luckily (or probably due to the oil leak) all the studs came off no problem in 15 mins - the six bolts holding the bottom of the manifold to the crossover pipe took me a further hour to remove, access was tight and they needed 2 grunts of effort to free off. 

Manifold off, problem was clear to see, one inlet was cracked and the other had actually broken!

Dropped it off at a local Exhaust Repair Specialist to be welded up as it’s made of Inconel Alloy - no such thing as cost savings in the 80’s it would seem, Porsche were a proper engineering firm back then. 

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New header tank and hoses fitted, I rationalised the air intake pipework a little to remove an extra couple of joins. Filter now sits in the space between the bumper and the wing hidden behind the arch liner receiving nice cold air. 

Everything fully reassembled and the final flourish is a new distributor sticker - what you didn’t think I’d remove all those bits without cleaning and painting them did you?

I have a new intercooler pipe sticker too, so will be fitting that when I’ve painted the pipe as it looks a bit scraggy next to everything else now. 

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That is coming together nicely.

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It's like a work of art.

 

* but only in so much as he's no fecking idea when he's finished.

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Back together and running like a dog - supper rich and constantly on the edge of a misfire. 

Borrowed a Smoke Tester from my Porsche Indy’s - it generates a harmless smoke and you hook it up to an airline to pressurise the system to find leaks in the intake and vacuum system. Handily I have a compressor tucked away in the garage and a retractable air line on the wall - naturally. 

Found a split hose under the throttle body and a leaking vacuum manifold - both now sorted and running improved a bit. 

Pulled the plug leads and they weren’t in great condition, fitted some new Bosch plugs and new Beru leads and everything “seems” ok now - needs a decent run out to test it, then an MOT. 

Opened up the ECU and made a couple of changes to enable the boost gauge on the dashboard, need to add a switch into the case to toggle between Bluetooth connection for the Head Unit and wired for the laptop as the Bluetooth is a bit flakey and drops out every now and then - not ideal when tuning and burning the config file to the ECU!!!

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This is getting waaaay too serious...   Are you going to apply the same electrickery wizardry to the 996?

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3 hours ago, Rachel said:

This is getting waaaay too serious...   Are you going to apply the same electrickery wizardry to the 996?

Nope - 996 electronics are much more modern and happily do their own thing with a hot wire MAF. 

This ECU would be overkill on a standard 944T but really supports the modifications I’ve made. 

Annoyingly, the cam gasket I used is an uprated multi layer steel one but they sometimes have sealing issues. Am still having a small oil weep from one corner of the cam tower so will whip it back off and change to a standard gasket that I already have. 

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Posted (edited)

Removed the fuel rail, distributor, drive belt and cam tower, replaced the gasket with a standard one and buttoned it all back up. Found a slight coolant leak from one of my new hoses too, replaced the jubilee clip and all sorted. 

Still running like crap, with massive oil blow-by. Seems to be running on 3 cylinders which would explain the huge overfuelling if one injector is spunking all it’s fuel down the exhaust. Pulled the plugs, yup - plugs 1,2 and 3 and black and oily, plug 4 looks like it’s done nothing. 

Compression tested all 4 cylinders and there is no compression on cylinder 4 - uh-oh. Best case scenario is a top-end rebuild/valve job, worst case (accounting for the oil blow-by) is knackered piston rings/damaged bore liner.

Will take the head off in June and investigate then, that’ll give me a better idea of what to do next as well as give me choices of dropping the sump to remove the pistons or dropping the whole engine and doing a full rebuild on a stand (which sounds scary/expensive but also something I’d quite like to do - albeit planned for and in a couple of years)!

 

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Edited by eldavo69

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