986 3.2 home engine rebuild

[PaulE]

I hink you made a wise choice with new lifters. If there were any particles or debris in your engine, you should consider a new oil cooler too. When my engine was rebuilt, they told me those were two areas that couldn't be counted on to get completely clean on the inside. And if you get a new oil cooler, you can potentially get a bigger one from a 3.4, 3.6 or 3.8 engine that will fit your engine and under your intake manifold.

[OldManMo]

Originally Posted by PaulE

I hink you made a wise choice with new lifters. If there were any particles or debris in your engine, you should consider a new oil cooler too. When my engine was rebuilt, they told me those were two areas that couldn't be counted on to get completely clean on the inside. And if you get a new oil cooler, you can potentially get a bigger one from a 3.4, 3.6 or 3.8 engine that will fit your engine and under your intake manifold.

Good call. I actually replaced the oil cooler when I did the IMS but the things I found as we stripped the engine makes me want to ensure everything is cleaned out. The next set of posts will explain why

I will be getting all parts ultrasonic cleaned and casings vapour blasted but I definitely will ensure all oilways are flushed and cleaned and if you hadn’t mentioned the oil cooler I would have stupidly put it back on as I only replaced it new a few hundred miles ago and no doubt it is contaminated

Thank you PaulE

[PaulE]

Originally Posted by OldManMo

Good call. I actually replaced the oil cooler when I did the IMS but the things I found as we stripped the engine makes me want to ensure everything is cleaned out. The next set of posts will explain why

I will be getting all parts ultrasonic cleaned and casings vapour blasted but I definitely will ensure all oilways are flushed and cleaned and if you hadn’t mentioned the oil cooler I would have stupidly put it back on as I only replaced it new a few hundred miles ago and no doubt it is contaminated

Thank you PaulE

My shop told me there was no way to be sure that the internals of the oil cooler would be completely cleaned of small particles, and a new one was cheap enough, especially compared to the cost of labor and parts for a full rebuild (no way I could do it myself in my lifetime!).

[Jgkram]

You’re setting a really high bar with your excellent attention to detail. I’m really curious to know how you got everything so clean on your suspension rebuild. I assume everything wasn’t replaced, was it? It just looks so good.

[bg305]

Originally Posted by Jgkram

You’re setting a really high bar with your excellent attention to detail. I’m really curious to know how you got everything so clean on your suspension rebuild. I assume everything wasn’t replaced, was it? It just looks so good.

agreed, it looks like a new car right off the line. kudos sir!

[bg305]

Here is what my chain guides looked like, maybe a bit less worn then yours but in the ballpark. My deviation on b2 was -9.27, I forget B1 but it was in spec (guides were worn the same as B2 though). Now my deviations are both ~1 degree



The other side w/o the oil holes were fine, both banks were like this.

When you put it back together note that the guides with the holes (and the o-ring) are put on the right sides of the tensioner. For B1 the the guide with the holes is on the "lower" side (away from the solenoid) and on b2 it is the "upper" (same as solenoid) as I recall.

[OldManMo]

Originally Posted by bg305

Here is what my chain guides looked like, maybe a bit less worn then yours but in the ballpark. My deviation on b2 was -9.27, I forget B1 but it was in spec (guides were worn the same as B2 though). Now my deviations are both ~1 degree



The other side w/o the oil holes were fine, both banks were like this.

When you put it back together note that the guides with the holes (and the o-ring) are put on the right sides of the tensioner. For B1 the the guide with the holes is on the "lower" side (away from the solenoid) and on b2 it is the "upper" (same as solenoid) as I recall.

Good shout about the holes, it would have been an easy (and impacting) mistake to make.

thanks for the heads up, very valuable info

[OldManMo]

Originally Posted by Jgkram

You’re setting a really high bar with your excellent attention to detail. I’m really curious to know how you got everything so clean on your suspension rebuild. I assume everything wasn’t replaced, was it? It just looks so good.

Actually, all the suspension/brakes were replaced with new, except for the callipers which I stripped and refurbed with all new parts and the wheel carrier which I bead blasted clean. So that is:

Coils, dampeners, handbrake cables, all handbrake components, discs, pads, shoes, sensors, all suspension arms, bushes, brake shields, speeds sensors, heat shield, cat converters, O2 sensors, gear shift cables, all (I think) mounting brackets (plastic and metal) and every nut, washer and bolt.







The only parts I didn't replace with new are the diagonal braces (they were in good condition and needed a clean), anti roll bar and the diamond brace. .The rear sub frame did need to be replaced as the roll bar bracket bolts snapped and they could not be tapped out (photo) but I was soooo lucky as I found two NOS items that were only £60 each instead of £800 each

[bg305]

Your work looks great, I can't wait to see how this comes out!

I just replaced the variocam guides / cam chains and chain tensioners (The 3 for the ims chain, and b1 and b2 ims to cam - I highly recommend changing them out if there are any signs of reduced tension on the chains (chain slap on startup, etc). While I was seeing some plastic in my oil filter it was a sudden chain noise and raspy? sound to the engine note that had me pulling everything apart. My variocam guides looked similar to yours but were still intact. I do believe the chain noise was because one of my tensioners was failing or had failed). My 01s had 50,300 mi on the clock when I took it apart earlier this year. I did not go as far as removing the heads as you are doing.

Couple of thoughts / questions reading your post.

1. you mention that you "redone all the soft touch paint" - does this mean you had the sport design option with the white / speckle finish? I used testors 1830MT on mine, came close.. but not all the way there.. I had a thread here: http://986forum.com/forums/show-tell-gallery/76906-new-headunit-usb-mic-integration.html Any-rate, I was curious if you have the same which paint you used. In addition to a smuge on the double din that is driving me nuts there are spots on the center console where the original sport design paint has been worn away.. I want to take the console out and respray, but would like to find a closer paint match.

2. You mention the oil gunk in the variocam tensioner, lifters, etc.. I also noticed how "brown" your carrier and the top of the head is. Mine was not like this at all. No oil sludge at all.. I am curious what you find, do you think it is possible there might have been some intermix with coolant at point earlier in the cars life? I saw no sludge anywhere, my variocam tensioners were nice and clean (did not stop me from giving them a good cleaning anyway). And I replaced one questionable lifter.

Here is an image from my engine, 50k on the motor, but it is only 20k miles different.
This one is with the new chain / guides:


this one was taken right after I removed the first bank cover, had not removed anything yet.


BTW, I also snagged the fuel return line dropping the engine but on the ebrake cable.. broke the seals on my injectors and fuel was dripping out. Luckily just getting new seals and re-seating the injectors took care of it.

Your son looks like he is having a blast! I tried to get mine involved (only a year older, 12).. He came down once or twice, was curious about how everything worked, but did not seem motivated to stay with it We do get to share other hobbies though so I can't complain .

[OldManMo]

Originally Posted by bg305

Your work looks great, I can't wait to see how this comes out!

I just replaced the variocam guides / cam chains and chain tensioners (The 3 for the ims chain, and b1 and b2 ims to cam - I highly recommend changing them out if there are any signs of reduced tension on the chains (chain slap on startup, etc). While I was seeing some plastic in my oil filter it was a sudden chain noise and raspy? sound to the engine note that had me pulling everything apart. My variocam guides looked similar to yours but were still intact. I do believe the chain noise was because one of my tensioners was failing or had failed). My 01s had 50,300 mi on the clock when I took it apart earlier this year. I did not go as far as removing the heads as you are doing.

Couple of thoughts / questions reading your post.

1. you mention that you "redone all the soft touch paint" - does this mean you had the sport design option with the white / speckle finish? I used testors 1830MT on mine, came close.. but not all the way there.. I had a thread here: http://986forum.com/forums/show-tell-gallery/76906-new-headunit-usb-mic-integration.html Any-rate, I was curious if you have the same which paint you used. In addition to a smuge on the double din that is driving me nuts there are spots on the center console where the original sport design paint has been worn away.. I want to take the console out and respray, but would like to find a closer paint match.

In terms of the soft touch paint, I had the rubbish finish (which was great when it was new) that turns into a gluey gooey gunk







I removed of each part, re-painted with black plastic paint then applied a new soft touch top coat that made them look an feel oooooooohhhhhhh, so nice. Can spend hours just gently stroking each plastic part and rubbing my face against it...velvet....erm....ok forget all that







I removed all plastics on the dash, doors, etc and gave them the same treatment



The top coat I used was this one and when it cures it is super tough as I had to sand a bit back which was near impossible but at the same time it was sooooooooo sooooofffffffttttttt and like velvet

[OldManMo]

also did similar to things like gear stick

[OldManMo]

Originally Posted by bg305

2. You mention the oil gunk in the variocam tensioner, lifters, etc.. I also noticed how "brown" your carrier and the top of the head is. Mine was not like this at all. No oil sludge at all.. I am curious what you find, do you think it is possible there might have been some intermix with coolant at point earlier in the cars life? I saw no sludge anywhere, my variocam tensioners were nice and clean (did not stop me from giving them a good cleaning anyway). And I replaced one questionable lifter.

I noticed that, mine all had this yellow almost like yellow passivate finish to everything. there was no suggestion at all of a coolant leak but the only thing I can think of is that an oil additive was added, something like a hydraulic lifter additive. In any case all that yellow came off in the degreaser with no resistance at all