Hilton

Great work - having got to the "drive for 500m" stage is huge, given the unknowns and mechanic-butchery you've had to overcome.

Really enjoying the thread.. do you have a to-do list to get to the point of passing inspection?

rufrob

Well. Turns out I had a pristine shifter cable from a 944. So that's done
But I wasn't getting any oil pressure. I swapped the wires and when I removed the switch for cleaning very bad oil came out. And it would stall when hot and wouldn't restart. I got the flywheel back and measured 0.3mm of play on the crank. Now the engine spins much freer but still no oil pressure. But I could feel something from the oil filler cap. I guess it's the thrust bearing.
I have a spare engine from the parts car and so far it turns smoothly and didn't appear to have any end play. So the plan is to do the head gaskets, and valve seals on it, possibly the crank bearings. Trouble is I want to do it at home. I bought an engine stand and will have to borrow a hoist.

Mrmerlin

that oil looks like thrust bearing failure.

NOTE depending on the miles on the other engine swapping the bearings might not be something to do, but a yes to headgaskets

rufrob

The spare engine has about 87000km or about 54,000mile. It's from a MY 1988. Should I change the valve seals? If so, can I do it without the special tool? I can borrow a spring compressor but worry about installing the seals.

rufrob

I got into the spare engine. Oh dear. Broken water pump impeller and an incredibly dirty engine.

Mrmerlin

is that the impeller thats all crumbled at the pump area if the volute surface is not damaged it may be fine that said the head gaskets are probably ready for renewal

rufrob

Got a lot of cleaning and right head off today.
Guess the oil pan gasket was leaking.

rufrob

Here are today's pics

rufrob

Those valve keepers are a PITA. But I got them done. New valve seals and head gasket done on the right bank. Tomorrow the left gets torn done.

Red Flash

Hi Rufrob! Inspiring work there.

On the block side, the surface of the cylinder head to the block looks good.

On the head-side, the firerings look fine. But are you planning on doing anything about the pitting? It looks quite deep.

rufrob

Unfortunately I don't plan on doing anything about the pitting. I showed the heads to chief/old mechanic. He doesn't know anyone in Japan who can weld them and so long as the mating surfaces are flat they should be fine. He has seen worst.
I did the left side last week. Still took 4 hour to replace the valve seals and clean the valves and seats.
I put the heads back on, cams as per markings,
I was supposed to take a summer vacation to Okinawa but typhoon 24 cancelled that.
A break in the rain this morning allowed me to strip the top of the original motor and put the car on jack stands. All you guys with your own garages, please remember how fortunate you are.
Next borrow the an engine crane from a neighbor. Do the oil pan gasket on the new motor then swap them. Wonder how long that's going to take me.

rufrob

The engine crane didn't materialize but a 3 day weekend and good weather did so out the engine came from the bottom. Don't remember the 944 was this hard. The 928 suspension is more difficult to handle.

rufrob

Here are some pics

Majestic Moose

Nice work, you've got it tough in a far flung land and without a shop hoist! When there is a will there is a way

rufrob

Cam and ignition timing, oiled pistons&cylinders and cams, vacuum hoses, vinegar soaked and cleaned fuel rails, cleaned and painted injectors, heat resistant painted valve covers( scratched on installation), radiator flushed and cleaned, suspension torqued, spark plugs and ignition wires, fresh oil all done. Engine rotates smoothy, timing marks line up on second rotation
To be done are destroyed power steering low pressure line, crank bolt torque, hall sensor connector, coolant refill.
What am I missing?