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How to rebuild an engine - a pictoral journal

 
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Chrenan  



Joined: 15 Jan 2003
Posts: 3899
Location: Canada

PostPosted: Tue Aug 01, 2006 8:27 am    Post subject: How to rebuild an engine - a pictoral journal Reply with quote


Spare engine removed from parts car


Spare engine on stand


Head removed from spare engine - bottom


Head removed from spare engine intake side


Head removed from spare engine exhaust side


Head removed from spare engine - front


Head removed from spare engine - back


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - bottom


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - intake


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - exhaust


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - valves


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - intake


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - exhaust


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam - springs


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam cam


Head back from European Motorworks (Eurorace) - 44/37 mm valves & Stage 1 cam top


Bottom end disassembly


Bottom end disassembly caps removed


Bottom end disassembly crank and pistons removed


Bottom end disassembly top


Block back from machine shop top exhaust side


Block back from machine shop top intake side


Block back from machine shop bottom exhaust side


Block back from machine shop bores


Bottom end assembly crank


Bottom end assembly crank


Bottom end assembly oil pickup


Bottom end assembly oil pickup


Bottom end assembly 9.3:1 euro spec pistons


Bottom end assembly 9.3:1 euro spec pistons


Bottom end assembly rear crank seal


Bottom end assembly oil pump and front crank seal


Bottom end assembly oil pan intake side


Bottom end assembly oil pan exhaust side


Bottom end assembly oil pan front


Bottom end assembly oil pan back


Bottom end assembly crankcase breather


Bottom end assembly water pump and alternator brackets


Bottom end assembly alternator bushings


Head assembly block off plate and fuel line holder


Head assembly distributor housing


Head assembly coolant flange


Head assembly thermo time switch and temperature sender


Head assembly oil pressure sender


Head assembly thermostat housing


Head assembly front seal


Head assembly cam pulley


Head assembly head mated to block


Engine assembly coolant transfer tube and intake side engine mount


Engine assembly rear coolant hoses


Engine assembly exhaust side engine mount


Engine assembly exhaust studs


Engine assembly exhaust manifold


Engine assembly timing belt and crank pulley


Engine assembly intake manifold


Engine assembly throttle body


Engine assembly warm-up regulator


Engine assembly auxiliary air valve


Engine assembly cold start valve


Engine assembly injectors


Engine assembly clutch bracket


Engine assembly thermostat upper housing and bleeder hose


Engine in place


Engine fully installed
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1987 951 - M193 Version for Japan
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Lizard  



Joined: 03 Nov 2002
Posts: 9364
Location: Abbotsford BC. Canada

PostPosted: Tue Aug 01, 2006 10:00 am    Post subject: Reply with quote

I like your badge replacement, cannot be lifted by petty thieves.
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3 928s,
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Chrenan  



Joined: 15 Jan 2003
Posts: 3899
Location: Canada

PostPosted: Tue Aug 01, 2006 11:51 am    Post subject: Reply with quote

It was a previous owner modification, probably the only good thing he did for the car. When I put it back to the original colour it will be totally de-badged, I like the clean look.
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1987 951 - M193 Version for Japan
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ideola  



Joined: 01 Oct 2004
Posts: 15451
Location: Woodstock IL

PostPosted: Thu Apr 30, 2009 12:18 am    Post subject: Reply with quote

Chrenan, did you have Eurorace do any porting, or was it simply the valve work and assembly of the head?

Also, on your Audi 5000 big bore throttle body, have you had any longevity issues with the fitment of the stock 924 rubber boot that mounts directly to the TB?
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88 924S SE | 82 931 Holbert | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Thu Apr 30, 2009 12:57 am    Post subject: Reply with quote

Awesome!

Shame it's hidden in the engine bay!

did you skim the block to up the CR any?

I had a big audi TB, while the intake pipe was a squeeze it was perfectly adequate and suffered no ill effects from being stretched over..
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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Chrenan  



Joined: 15 Jan 2003
Posts: 3899
Location: Canada

PostPosted: Thu Apr 30, 2009 1:35 am    Post subject: Reply with quote

Nope, didn't skim the block at all. It was a fairly mild build. I'm happy with how it turned out, still running strong, pulls really well.

I still have the engine that came out of the car, so when I have the time and inlcination, that one will be bored out, stroker crank, custom pistons and either another big valve head or a 931 head.
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1987 951 - M193 Version for Japan
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ideola  



Joined: 01 Oct 2004
Posts: 15451
Location: Woodstock IL

PostPosted: Thu Apr 30, 2009 1:37 am    Post subject: Reply with quote

ideola wrote:
Chrenan, did you have Eurorace do any porting, or was it simply the valve work and assembly of the head?

Also, on your Audi 5000 big bore throttle body, have you had any longevity issues with the fitment of the stock 924 rubber boot that mounts directly to the TB?

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88 924S SE | 82 931 Holbert | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition
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Chrenan  



Joined: 15 Jan 2003
Posts: 3899
Location: Canada

PostPosted: Thu Apr 30, 2009 12:26 pm    Post subject: Reply with quote

Ports were hogged open as well I believe, not actually sure, old school 80's techniques .

The same rubber boot has been on since the engine went together, it was new on installation and shows no adverse wear from the larger throttle body.
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1987 951 - M193 Version for Japan
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Power Tryp  



Joined: 16 Apr 2009
Posts: 430
Location: Calgary, Alberta

PostPosted: Thu Apr 30, 2009 4:02 pm    Post subject: Reply with quote

Any plans in place to get it dyno'd? I know I for one would love to see what kind of power it makes. I am a bit on the biased side of that having worked closely with the owner of dynoplus (engine dyno only) and being friends with the owner of SCP (engine and two wheel chassis dyno) here in Calgary.

Tryp
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Melanie - 1980 931
Scrappy - 1980 924 shell
NoName - 1980 931 (seeking rebuild)

Green tartan interior, you don't see that on a Civic.
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Chrenan  



Joined: 15 Jan 2003
Posts: 3899
Location: Canada

PostPosted: Fri May 01, 2009 1:01 am    Post subject: Reply with quote

No plans to get it dynoed, but it would be interesting. I'd have to find a dyno that reads that low!
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1987 951 - M193 Version for Japan
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Power Tryp  



Joined: 16 Apr 2009
Posts: 430
Location: Calgary, Alberta

PostPosted: Fri May 01, 2009 4:25 pm    Post subject: Reply with quote

Oh i'm sure it'd be no problem, if they can find out the power of a smart car then i'm sure they can find out what power yours makes. Personally I'm not interested in the HP from your engine, I wana see the torque #s that It produces.

Tryp
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Melanie - 1980 931
Scrappy - 1980 924 shell
NoName - 1980 931 (seeking rebuild)

Green tartan interior, you don't see that on a Civic.
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smither  



Joined: 03 May 2009
Posts: 26
Location: Pontyclun, Wales, UK

PostPosted: Mon Oct 12, 2009 2:23 am    Post subject: Reply with quote

Hi Chrenan

Really great pictures, i was looking at the exhaust ports on your new big valve head and it seemed to me that they had been enlarged and rounded off. I also noticed that you appeared to use a stock exhaust manifold (i think you call them headers in the US), could you tell me what gaskets you used and if you did anything to them to match the ports?

Thanks
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1978 NA 924 dogleg
1971 Triumph Gitfire with ashley hardtop
2000 MGF (for the wife)
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