Shaun @ Tru6

Hello everyone, I've been a 911 guy for a long time. Recently, a shop I worked at years ago asked me to sell a car for one of their customers, an elderly gentleman. A 91 928 S4 that has sat in his garage for 7 years. Looking at it I quickly realized it wasn't a car I could sell but it was a car I could bring back to life. How different could a 928 be from a longhood? What could go wrong?

So I way over-paid for it and the journey began about a month ago. Here's the story and I hope I can get some help on the last few feet of the mile.

My shop is on the second floor and I've built a winch system for each flight of stairs to get 911 motors up. Even with a flat tire in the back, was able to get it up on the trailer myself using the top level of my stairway winch system, worked better than I could have asked for. Things were good.

Shaun @ Tru6

Just like an early 911, I already feel at home.

Shaun @ Tru6

about 15 gallons later. The gas was quite bad but not turpentine yet.

Shaun @ Tru6

New fuel filter
Bench cleaned the old fuel pump
Fresh oil and filter
New battery

Turned key.

Fired right up. Ran rough for 20 seconds and then evened out. Ticking on right side valve cover so a sticky lifter I'm sure.

Absolutely glorious sound, just at idle.

After running for a bit, found that #3 fuel injector is stuck open. Plug is wet, left side tailpipe is wet and sooty. All other plugs looked great. Surprised about #3 because it was running very smoothly, but that plug was not firing.

Shaun @ Tru6

Then I was warned about the timing belt. Talked with Roger at 928srus and he put together a timing belt, waterpump and fuel line package for me.

First day was a good day, not a terribly hard job so far. Driver side cam rotated after taking the belt off, have good white marks so not concerned when it all goes back together.

Wish I had the time to tear much more of it down just for cleaning and replating.




A jungle of belts and adjusters. Not Porsche's best work.




45 degrees as a safe place where valves can't hit pistons.




These white marks are going to come in handy.







Flywheel locked down.




Done for the day. You can see the driver side sprocket is off.

Shaun @ Tru6

here is where the fun (for me) begins. No sense in putting the car back together with dirty, grimy, rusty parts.













This little switch was captive in the cage. Had to bend back the little tabs to free it and clean the cage.







Everybody in the pool.

Shaun @ Tru6

Parts after 2-step process starting out with pyramids and then going to bevel cut cylinders with some wire brushing and bead blasting in between.

All pretty much ready to bring to the plater.

Shaun @ Tru6

Nothing better than all new hardware to bring some joy into the job.

Shaun @ Tru6

Waterpump went on with no drama, it look longer to clean the block mating surface than to get the pump on. Then it took 3 tries to get the timing belt on correctly, which must be installed tightly as you go. Not so easy. As it sat, the right cam is a half tooth off but when you manually engage the tensioner, the mark falls into place. Such a good feeling. Taking Roger's advice, I had opted for the PorKen automatic tensioner. I got the one that deletes the air pump.








Left side bank marks line up nicely.




Right side is half a tooth off.




Manually tensioning the tensioner, pin is still loaded




Marks line up nicely now.




Ready to go once I pull the pin.

Shaun @ Tru6

A little more progress. I think the radiator will be the only thing to hold me up from getting it running. May use my leaking one (dribble) for testing once I get the injectors in.

Really enjoying the process. But as noted on while you are in there stuff, wish I had pulled apart the alternator mount and tumbled that. Winter project.

Pulled the pin and the stars aligned.








Original dipstick o-ring has seen better days.




I love little details, even if they'll be covered up. While I'm not a concours guy, the car needs a thorough detail...grime is everywhere.




Today's money shot




35 lb of junk

Shaun @ Tru6

This past weekend and today, finishing it all up.

Cleaning up all the engine bay plastic I took off




Radiator was leaking, was about to order a new one from Roger when my old friend Dave saves the day and sends me this one out of an 86.5 parts car he had. Old original Behr radiator on the right. Had to do some mods to the new Al one but it's great to have.




All the ancillaries installed. Again, wish I had taken so much more out and tumbled it or plated it.




Jewelry




Dave's radiator ready to go in.




In and running, have to get the fans in still.

Shaun @ Tru6

Now comes the hard stuff. Still have to do the injectors (got some remanufactured ones) and those should cure the hydro-lock. Once that's done I've got figure out the sticky lifter, figure out how to remove the air injection system and most importantly, figure out why none of the gauges work. And I know there will be a lot more.

It has be a great car to work on, I have a lot of respect for it. I'm hoping the last few miles of the marathon getting it back on the road will be easy ones.

rbrtmchl

Wow, looks great. Great work getting it back into running condition. Search on 'Swepco'. Others have used it to free up a sticky lifter.

ezdriver

Wow! Simply wow! I am in awe.

jbrob007

What an improvement! Nice job!