granprixweiss928

Work on the engine continues over this past long weekend. My goal was to get everything that I had removed previously cleaned up and do more teardown on the motor.
Started cleaning all the bags of hardware I had, and the bucket of other small parts.





I assembled by valve covers so that I could put them on and clean the block and not get any water/etc in the valve train. Ill go back in later and apply sealant where needed and change the pins and the cam shaft end caps. Camshaft seals were recently changed by PO so they are good to go.




heres a look at the valve train:


On the engine I pulled the harm balancer, pulleys, air pump, brackets, timing belt, all covers and the tensioner. then began to clean. here is the front pre cleaning, not too bad.



and then I pulled the water pump. The pump was changed by PO 8K miles ago in 2011 and is a Laso. I wanted to check it and change the gasket. Its all good and has a plastic impeller. I will reuse it. The little allen head screw over the idler pulley was stripped but I get it out with an extractor.

pump-less and clean now:








I inspected the gears, the Cams are new! and the oil pump is great too.


I disassembled the tensioner and cleaned it all out. It needs a new boot, I found a small split about 1/4" long, as well as the rear O ring and the block seal.



the tensioner pulley is OK (despite visible wear) but the idler roller is noisy and I will replace it.


One of the reasons I pulled the motor was to repair the stripped coolant drain. Im putting in a Time Sert. I pulled the exhaust manifold and then drilled out the stripped threads using the bit in the time sert kit. Then I used the counter sunk cutter. I tried to then tap it but I didnt have a large enough handle so I quit for the night and will continue tomorrow.


Mark

Hilton

You can just replace the bearing in the idler pulley - its a common 6905RS bearing on the S4 (earlier cars with the older style of water pump idler mount use a 6303).

Just press it out/in with a couple of large sockets and a vise (or a press if you have access to one).

granprixweiss928

Thanks for the tip about the bearing.

granprixweiss928

projects completed

finshed repair of block drains, new sealing rings
Oil pan gasket replaced, pan cleaned
Valve covers re-installed, new gaskets/seals
removed old plugs
replaced pan seal for level sensor
installed water bridge, all new seals & sensors
installed oil filler neck, new seals
removed old crusty cam end plugs, installed pins, re-installed caps with loctite 574
installed tensioner arm with new idler roller bearing and new 4mm allen key bolt

I wanted to do more, but I played with my other 928 too much (clutch R&R).

granprixweiss928

Current status on engine rebuild...



started installing the fuel lines, wiring, vacuum lines, brackets, etc.

put intake back together.



I hope to reinstall the motor this weekend.

other thngs done-

installed timing belt and covers
installed new distro caps/rotors
tensioner with all new boot/seals and fluid
plug wires, new plugs
repaired cleaned and installed engine power harness

crushingday

looks great! keep me in mind this spring if you do indeed wish to sell it.

https://rennlist.com/forums/928-foru...s-3-000-a.html

granprixweiss928

Friday I completed the intake installation. Injectors are new Ford 19lb.


Then I pushed the car around and began cleaning/prepping the engine bay.


The crossmember was especially grimy on top where the steam cleaning could not reach. I removed it to clean it and get the collapsed mounts off. the strap holds up the exhaust and the TT.


cleaned up now. I pulled the coolant res and changed out several hoses under there for coolant and fuel vapor.


took engine off stand with hoist and then lowered down to change the RMS.


With the help (all day) of Speedtoys and Chalkboss we got the engine back in the car and secured in place in the dark after reinstallation of the crossmember. We changed a PS rack boot also. and then pushed the car into the garage to continue later...


to be continued...

granprixweiss928

Over that last two weeks I worked on the car every night and weekend, connecting the trans, exhaust system, repaired and cleaned wire harness, connected fuel line, cooling hoses, re-installed rad and fans, filled with oil/new filter, starter motor, Alternator, belts, PS pump, hoses and tank, throttle cables, vacuum lines, etc!

Last night I completed everything regarding getting the engine back in. Filled up all new fluids, and then tried to start it. On first start I had a fuel leak at the front regulator (fuel line not tight, should of checked that!) and on second crank it started but rpm shot up. I shut it down and called it a night.

Today I found the throttle sticking open due to a misaligned cable, and started again. and it started right up. Then I proceeded to continue to top off the ATF while it was running. Before it got too hot I checked the cooling system with a pressure tester and got a small dribble on the heater hose, that fixed with a slight tightening of the clamp.

I then let it warm up a bit and drove it out of the garage, where I let it warm up until the fans came on. Then I took it for a 20 minute drive and all was good! no leaks and running smooth. yay!









now on to other tasks on this car.

Hilton

Excellent - should have a nicely reliable car after all that work!

yardpro

Inspirational.

It is nice to have other 928ers close by.

I live in a 928 vacuum. No one even remotely close.

I am going to try and offer a free working beach vacation this summer to get a hand with my torque tube project

granprixweiss928

been driving it around. I like these S4s!

I got new [reman] axles because they made some noises backing up.
I pulled the old ones tonight and all the brake rotors ( they need surfacing)

the rear ABS wiring outer sheath has all fallen off and the wiring is loose. a couple wires were damaged by the axles. I pulled the ABS harnesses out to repair them.

Rear brake pads almost on the wear limits so I will replace them.

Mrmerlin

its a fun thing to debug your new ride,
once your done you will have one of the best cars you could ever want,
as its your handywork thats proven itself.
Thanks for posting the progress reports, your doing a great job!
Keep Em Flying!

granprixweiss928

Heres my ABS/brake sensor wiring:

damaged by the driveshaft ABS and brake pad light on, on dash


removed from car


repaired with silicone self fusing tape and spiral wrap:




rear suspension view


new reman axles

BC

What did you wrap those ABS loom wires with?

granprixweiss928

BC- look above. Silicone tape and spiral wrap.

Today I completed these tasks:

Axles installation, with new end nuts
repaired RR side marker light
repaired wiring to plate lights
drained tank of old fuel
changed fuel filter
installed resurfaced rotors
new rear pads
installed new charcoal Y pipe
replaced differential gear oil