checkmate1996

[QUOTE=high-brass]. First the water pump was leaking all the way around it. I had used the wrong type of Permatex sealant. I used a fast drying (yellow) sealant. QUOTE]

Al,

The last 3 WP's I've done I have not used ANY sealant. I just thouroughly cleaned the area and used the provided gasket. NO LEAKS. Also, our former MORPCA president has performed about 14 WP operations and also recommends not using a sealent and has had great success. YMMV!

Also no 928 markings most likely means a chinese knockoff...all of mine were rebuilt porsche parts with the appropriate 928 numbers...

Engine Looks great! Can't wait to see final product!

hacker-pschorr

Ditto - I do not use any sealant anywhere on these engines. Head gasket job in 2004, no leaks to this day. Well, none that I know of

Big AL in VA

Yesterday I found that the o-ring sent along with the thermostat was indeed the wrong size. I used a larger o-ring that came along with my engine gasket set. Now it is not leaking. I have heard arguments on both sides of the sealant question. Pardon the pun, but using sealant could be a water pump for dummies way of doing it. I admit falling into this. The spector of removing the front engine again to do the pump over is something I could not think about.

I started the engine up once again and so far no coolant leaks "YEAH". However, I found a new leak, a pin hole leak in a short fuel hose from the right side fuel regulator. This is no big thing.

Since I have the emissions waiver now from the state, I am pondering the removal of my high flow cats and then the removal of the smog pump hardware. The pump will remain as idler.

BIG AL from Virginia
84 928S EURO twin distributor monster with large valve cut outs in the pistons

UKKid35

I tried it without sealant and it leaked live a sieve. So I did have to remove the front of the engine and do it again, this time with sealant. Perhaps there are different gaskets of differing quality.

I had to remove the front of the engine a second time when I found that I'd installed the tensioner pulley bolt the wrong way and it was rubbing against the harmonic balancer.

Big AL in VA

Good news for me. I replaced the leaking rubber fuel hose and replaced the other rubber hose as well. And I am glad I did. Although it was not leaking, it had several cracks.

Ran the engine in our hot Virginia sun for at least 25 minutes. No overheating and no leaks. Thank God.

Now, since I got the emissions waiver from VA state. I am pulling the 2 high flow cats. And replacing with straight pipe. I have already removed the smog pump pipe and valve to the head check valve. So far so agonizingly good.

So, I will put up my high flow cats on sale soon. I paid 319.00 for the pair at 928 Motorsport and they only have about 30 minutes of motor idling time on them. So they are practically brand new.

This Friday I will get the registration and take it out on the street for the first time in 7 months. And as promised, once I get the intake runners and plenum polished up, I will take pics and post them here. And pics of the car and maybe Big AL.

BIG AL from Virginia
84 928S EURO twin distributor monster with large valve cut outs on the pistons

chewy8000

Nice work AL. It's been 4 months and still no heads yet. I'm dying to get mine back together as well.

Big AL in VA

Whats happening with your heads?
I had C&C machine shop in Manassas Virginia do mine. They ported and polished plus scotch brited the intake and exhaust ports. Faced off the mating side to the block. They charged me 1038.00. But that also included repairing where the bolt was jammed into the head.

Thank you for your kind remark. It has been a very tough ordeal for me. I am not as young as I used to be.

BIG AL from Virginia
84 928S EURO twin ditributor monster with large valve cut outs on the pistons

BeerFish

AL! If your heading out Friday lets school around.

Big AL in VA

I posted a new thread of the engine pics so that others who are not following this lengthy thread can enjoy the finished product. I hope this does not violate any policies, if it does, I apologize in advance.

Link to new thread and pics:
https://rennlist.com/forums/928-forum/359947-big-als-engine-pics-motor-done-no-leaks-sounds-strong.html

Please enjoy the pics and comments are appreciated.

Big AL from Virginia
84 928S EURO twin distributor monster with large valve cut outs in the pistons

Big AL in VA

Sounds good beerfish for another weekend. Friday will be a very busy day for me. I need to go to DMV and initially I will drive near home only unitl I have some confidence in the car.

BIG AL from Virginia
84 928S EURO twin distributor monster with large valve cut outs in the pistons

Big AL in VA

So far so good. I have about 500 miles on the engine and the oil level has not fallen and the oil color is only slightly darker. Timing belt has not shown any stretch so far. No loss in any coolant.
Also, I will be showing the car at the INternational Gold Cup by request of PCA executive director who saw my car at the Founders region historical event in Dulles, VA. A good incentive to get the detailers clay out and remove some swirls and small scratches.

Big AL from VA
84 928 S2 Euro twin distributor monster with large valve cut outs and 85 style headers, X-pipe