968 resurrection
06-21-2014, 09:10 PM
#1
Rennlist Member
Thread Starter
968 resurrection
Hi All.
After starting this project I have been encouraged to start a new thread for the resurrection process. I have never done anything like this (rebuild or the documentation) so please bear with me. These forums have been so helpful to me with my other P cars, that I think it fitting that I try to repay if I can.
About a year ago I found a 92 968 in a junk yard.Looking like a TB/WP job started. Well, actually I found it about 6 years ago and after years of hounding the owner, I bought it last year for my then 12 year old son and I to build for him. I have had an 87 924S, and currently have an 87 928S4.
The car owner contracted the Yard owner to fix it. The yard owner got stuck on the variocam, closed the hood and walked away from it. Tires still held air. Body straight, paint BAD. Interior mostly perfect, but carpet fibers turning to dust in the trunk. Seats Immaculate. It sat with the cam cover off and the front of engine mostly dis-assembled.
Fast forward 7 years and the car owner dies. I ran into the yard owner and asked about the car again. He then told me he would sell it. He said he put 3K into having the head rebuilt with new valves and seals. He did install the head and water pump. He had all of the parts for the TB change, installed the front seals and new or re-manufactured WP. It appears it had a TB failure, but the yard owner swore it was an internal failure of the Variocam.
I towed it away for 2K.
After many hours of research and inspection, I am positive that it was a TB fail and not the variocam. Cam shaft teeth show no abnormal wear. I took it all apart, changed the pads and chain. Tore down the lifters, and cleaned them. Inspection of the pistons and cylinders was done. Cylinder walls show no scars or scratches of ANY kind. Engine turns smoothly. Piston tops show minor nicks from apparent valve smash. Thoroughly cleaned head, re-installed with new nuts, re-installed cams using homemade saddle clamps to evenly press cams down. Found alternator wires in harness devoid of any insulation.
The build process will be slowwwww. I am committed to my son being involved with all aspects. He is excited. However, with our schedules and my frequent travel with work, it will be hard. I suspect that we could put everything back together and turn the key for a test if we had 3 good days of production.
I took the Oil tower off because it was a leaker on my 924. Gonna do some WYIT, but don’t want to go nuts in case this cars turns out to be a loss. My 928 is sitting waiting for me to start the intake refresh, along with motor mounts, P/S rebuild, Oil pan studs, TB/WP with NEW gears and motor re-install…..lol
So, currently, I have temp installed all of the gears and parts for the TB. I will go through the motions of everything just so it goes smoother for him. Cams went in smooth with correct alignment and 7 teeth to marks. Temp install of Cam gear has it lining up directly with reference on back cover. Hall sensor looks great.
TDC set and verified from bottom of motor reference mark in little window.
Next. I have to go through all of the box of hardware and match part numbers of bolts to parts diagrams. (I scoured the junk yard for 5 hours collecting parts!!) Re-make the Alternator harness with #6 copper, lock down flywheel. I will probably do a test flow on injectors, but may send them to Witch hunter right off the bat. There were many nests from mice in the engine bay. Didn’t find ANY chewed wires. So far, all electrics bar the alternator harness look great and no signs of crumbling. (My 928 has tons of heat damage to wiring.) Fuel hoses will be replaced after successful start. Then if all goes well, the rest of the hoses and vac lines.
All comments and suggestion are welcomed. Pics to follow.
If this post is not welcomed, just let me know and I will delete..
Thanx All.
You are awesome!!
John
After starting this project I have been encouraged to start a new thread for the resurrection process. I have never done anything like this (rebuild or the documentation) so please bear with me. These forums have been so helpful to me with my other P cars, that I think it fitting that I try to repay if I can.
About a year ago I found a 92 968 in a junk yard.Looking like a TB/WP job started. Well, actually I found it about 6 years ago and after years of hounding the owner, I bought it last year for my then 12 year old son and I to build for him. I have had an 87 924S, and currently have an 87 928S4.
The car owner contracted the Yard owner to fix it. The yard owner got stuck on the variocam, closed the hood and walked away from it. Tires still held air. Body straight, paint BAD. Interior mostly perfect, but carpet fibers turning to dust in the trunk. Seats Immaculate. It sat with the cam cover off and the front of engine mostly dis-assembled.
Fast forward 7 years and the car owner dies. I ran into the yard owner and asked about the car again. He then told me he would sell it. He said he put 3K into having the head rebuilt with new valves and seals. He did install the head and water pump. He had all of the parts for the TB change, installed the front seals and new or re-manufactured WP. It appears it had a TB failure, but the yard owner swore it was an internal failure of the Variocam.
I towed it away for 2K.
After many hours of research and inspection, I am positive that it was a TB fail and not the variocam. Cam shaft teeth show no abnormal wear. I took it all apart, changed the pads and chain. Tore down the lifters, and cleaned them. Inspection of the pistons and cylinders was done. Cylinder walls show no scars or scratches of ANY kind. Engine turns smoothly. Piston tops show minor nicks from apparent valve smash. Thoroughly cleaned head, re-installed with new nuts, re-installed cams using homemade saddle clamps to evenly press cams down. Found alternator wires in harness devoid of any insulation.
The build process will be slowwwww. I am committed to my son being involved with all aspects. He is excited. However, with our schedules and my frequent travel with work, it will be hard. I suspect that we could put everything back together and turn the key for a test if we had 3 good days of production.
I took the Oil tower off because it was a leaker on my 924. Gonna do some WYIT, but don’t want to go nuts in case this cars turns out to be a loss. My 928 is sitting waiting for me to start the intake refresh, along with motor mounts, P/S rebuild, Oil pan studs, TB/WP with NEW gears and motor re-install…..lol
So, currently, I have temp installed all of the gears and parts for the TB. I will go through the motions of everything just so it goes smoother for him. Cams went in smooth with correct alignment and 7 teeth to marks. Temp install of Cam gear has it lining up directly with reference on back cover. Hall sensor looks great.
TDC set and verified from bottom of motor reference mark in little window.
Next. I have to go through all of the box of hardware and match part numbers of bolts to parts diagrams. (I scoured the junk yard for 5 hours collecting parts!!) Re-make the Alternator harness with #6 copper, lock down flywheel. I will probably do a test flow on injectors, but may send them to Witch hunter right off the bat. There were many nests from mice in the engine bay. Didn’t find ANY chewed wires. So far, all electrics bar the alternator harness look great and no signs of crumbling. (My 928 has tons of heat damage to wiring.) Fuel hoses will be replaced after successful start. Then if all goes well, the rest of the hoses and vac lines.
All comments and suggestion are welcomed. Pics to follow.
If this post is not welcomed, just let me know and I will delete..
Thanx All.
You are awesome!!
John
06-22-2014, 12:44 AM
#6
Rennlist Member
Thread Starter
When I bought my 928 it had been parked for 2 years. I flew 700 miles one way. spent 4 hours prepping it, chasing the mice out of it, splicing ignition wires, etc.
Drove home no issues. Promptly parked it spent 6 months doing carpet cleaning, rewiring harness' that got totally chewed from the mice, fuel hoses etc, Daily driver for 2 years until I decided to pull the motor to catch up on all of the unknowns. All will be good,,hahah
Drove home no issues. Promptly parked it spent 6 months doing carpet cleaning, rewiring harness' that got totally chewed from the mice, fuel hoses etc, Daily driver for 2 years until I decided to pull the motor to catch up on all of the unknowns. All will be good,,hahah
06-22-2014, 04:33 AM
#7
When I bought my 928 it had been parked for 2 years. I flew 700 miles one way. spent 4 hours prepping it, chasing the mice out of it, splicing ignition wires, etc. Drove home no issues. Promptly parked it spent 6 months doing carpet cleaning, rewiring harness' that got totally chewed from the mice, fuel hoses etc, Daily driver for 2 years until I decided to pull the motor to catch up on all of the unknowns. All will be good,,hahah
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06-23-2014, 07:23 PM
#14
Rennlist Member
Wow. The yard owner left the cam cover and intake manifold off...for 6+ years?
From your introduction, it doesn't sound like you plan to pull the motor. Are you planning to clean/flush the internal engine passages? Also, having been left exposed to the elements for so long, would it not be prudent to change rod and main bearings?
From your introduction, it doesn't sound like you plan to pull the motor. Are you planning to clean/flush the internal engine passages? Also, having been left exposed to the elements for so long, would it not be prudent to change rod and main bearings?
