I thought i would start a thread to document and update you on my '91 GT. As many/most of you know I have had this car for about 8 years. I bought it with about 125k miles and it now has 170k. About a yeat after getting the car I worked with Dave Roberts of 928 Specialists to develop and install his twin screw supercharger kit. In that form it put down reliably about 440 RWHP.

Last winter I upgraded the supercharger to a 2.1l (from a 1.7l) and put down nearly 500 RWHP and 500 RWTQ! It's a monster and hoot to drive.

The car has been quite reliable except for a few relatively minor things here and there. However this past SITM, the intercool developed a leak inside the intake manifold and it prevented me from joining the fun run. Luckily I had my sharktuner with me and after taking a whole bunch of timing out and remapping the fuel, I made it home. I could hear some knocking under acceleration after it was fully heatsoaked.

Since it's time for a timing belt, water pump, oil pan gasket, and other things, I thought it best just to pull the motor and do complete teardown and rebuild.

Since I have the Devek L2 headers, I decided to leave them on and drop the engine through the bottom rather than spend 6 hours cussing and swearing and pull the motor through the top. I'm not sure if it saved any time, but it was less dramatic for sure. I'm already thinking it might be easier to re-install it from the top, but time will tell.

Here are some of the pics from the engine-ectomy.









I used my home-made engine support bracket to hold the engine from above while I disconnected the cross member. It worked great!





Then I took the clutch out. Each time it gets easier and easier...



With 500 "torques" these splines look just fine.



I used to have issues with the power steering being difficult from time to time. I think I see why. The line/hose between the two ends is totally crushed. This is the first time I've had this out for inspection... Oops.





Oh yeah... split tie rod boots too... Add that to the list.





Then about 2 hours ago... it gave birth... or maybe it's more of an abortion...

 

Nice. I too have been contemplating dropping the motor out the bottom.

 

Looks like fun Andrew, keep us updated as you do this.

What clutch were you running and how thin is that disk?

 

ackh !!!! you left your pressure gudgeon the fuel rail…..say it aint so!!


very neat, was the engine removal less or more trouble this way…..

I wish I had your talents man!!

 

It's a little less hassle since you don't have to take the front of the engine off. The alternator and PS can stay on. Just disconnect the 14-pin. On the other-side, you do have to drop the steering rack... so I can't say it saves time, but I was dreading having to take the headers off.

It's a Spec Stage 3+. The Flywheel was already at it's minimum when I installed it (dumb shop took it down to the minimum spec! ) I think it will have to be replaced. Haven't looked any anything else. I'll post when I do. Tons of carbon dust came out... cough cough...

Yeah... I know. The gauge is coming off and getting replaced with a better setup or none at all.

Removal was about the same... just different hassles. At least I didn't have to deal with headers.

Ok... off to the showers, and get prettied up for the party tonight! Woo Hoo!

HAPPY NEW YEAR!

 

Looks good. I took an engine out the bottom of two cars. Second was because I couldn't get the bell housing bolts off. I was going to say remember to take off the TT bolts but you left all that in. Good show.

New rings? Mains? Rod bearings? Rod bolts? Cometic Head gaskets? Obviously all seals. At 170 I would look at all that, and I think GB would say so as well, maybe.

People will say 300k, yes, but if you have the opportunity...

 

other than having 170k miles......was there another issue that makes you think it needs full rebuilding.... Bill Ball put around 50k on his 928 boosted and has over 240k and counting with no issues? The engine in my old S4 had about 130k on the clock with perfect compression (200psi) and leak down (3-4%)

when properly maintained (like yours) these cars run forever....it takes a serious mistake to damage them...think severe overheating, super old corrosive coolant eating head gaskets, oil starvation from track driving, or unlucky timing belt-thurst bearing issues...

 

Looking good Andrew.......do you have pics of the lift you used to drop the engine?

 

I blew a supercharger belt once...........





Its great knowing when you have it all back in you have done it right!
Happy new year!

 

How did you build that engine hoist? I am going to do the oil pan gasket sooner than later on my 81 and would like to know how to build a hoist.

 

Nice work, just a little project for the winter..

 

I has the engine out about 5 years ago and did the cam seals and rod bearings. I didn't know enough at the time to check valve guides. I plan to do every thing except maybe mains. Rod bearings are probably okay, but inspection will show. Cams might also be in order which means maybe springs too. I got a smokin deal on a full set of porche rings, so that's going in for sure. The possibilities are endless...

I get quite a bit of blowby and oil ingestion which makes me think the rings need replacing and possibly valve guides and guide seals (for sure). I agree with you though, being properly maintained these car go and go.

Get a 8' 4x4, 2 big long eye bolts, 2 lengths of chain, and 2 mast links, some nuts and washers. Cut the 4x4 to fit the bay width (I added a couple 2x4 feet to make it a bit higher) then drill for where the hoist points are located. Done! Cost about $25. Works on 16v too, just different locations.

Hey... If you are still looking for a set of headers... Now is the time to get these back. Just let me know.

 

Good boy Andrew!

 

Engine is on the stand and fluids are draining.

Now that I have a closer look at thing... holy crap it's dirty. The oil cooler was clearly leaking, the tensioner also appear to have leaked. I see some oil under the water bridge, but none in the V, so my guess is the oil filler plate has sprung a leak.

I need to clean up my workshop in the basement before I start taking too much stuff off. Plus its snowing... Yuck!

 

Andrew-

Get some plastic bags and rubber bands, seal up the AC toses and connections. Keeps junk from migrating in to where it can do some real damage.

The pinched PS line on the rack looks like the equalizing line. Relatively low pressure, but there isn't much room in the crossmember for repairs. Guessing also that the line isn't a normal service part. Maybe Mark A has one from a front-crunched car with a non-rebuildable rack.


Have fun! Watching the wx reports for Michican, looks like plenty of hibernation opportunity in the basement with wrenches.

Take 0plenty of pictures, please!