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986 3.2 home engine rebuild
I know, this will only be my second post and it will be about a full tear down and rebuild of the engine in my 2001 Boxster S....at home in my garage..in the UK.
Must be a madman :) So, this is not my first full engine rebuild, Ive done many though admittedly only on Mercs, BMWs and Audis, though a few of those were also performance engines. So lets put some context the insanity. I owned a 2000 Boxster S from new and loved it, then marriage came along, as did the sensible cars, then divorce and then thought, wouldn't be great if I could get a S for my sons first car (he s currently 11) and he can work on it with me restoring it, learning and feeling responsible for it So last Aug, I bought a 2001 S with 70k on the clock, but I could see it needed lots of TLC. Got it home, drove it for a couple of months and then in the garage, gearbox out and IMS fixed with new flywheel, clutch, complete rear suspension, brakes refurb, cats, nuts, bolts, clips, washers, power steering, air con, front rads, air con rads, etc, etc. redone all the soft touch paint, double din stereo, dyed the leather, etc, etc Basically almost spent the cost of the car in parts for the rear end, but I looking at the learning and memories with my son which are priceless. So between my son and I we took the car from this as am example http://986forum.com/forums/uploads02...1637179595.jpg http://986forum.com/forums/uploads02...1637179641.jpg http://986forum.com/forums/uploads02...1637179699.jpg to this http://986forum.com/forums/uploads02...1637179977.jpg http://986forum.com/forums/uploads02...1637180001.jpg http://986forum.com/forums/uploads02...1637180022.jpg The car was so much better and we enjoyed for the summer and even though it sailed though its MOT with low emission values, something wasnt right, there was a slight rubbing sound (I dont know how to describe it :)), So I checked the timing and it had a -12 deviation, I adjusted the timing (stupidly with the engine in the car) and got it down to -8.4. It also felt low on power and a few drops on the curve and the fumes smelt wrong. So loads of research and might be the chain guide, might be valve seals, might be rings, etc One thing for it, engine out and tear down and what I discovered was wow, not a really bad wow that many have shared but still, wow. And this brings us to this thread, I would like to share the experience with you all as it may help others, ask for you to look out for me in case you spot something I miss or I am about to balls something up:) Thanks in advance and here we go...BTW the engine is already almost torn down so no turning back now :D |
So first thing to do was gearbox, bumper and exhaust out. This only took a couple of hours..what? you say, thats BS.
No its not as I already spent over 3 weeks doing the first time, breaking ever bolt, stud, etc and spending days to do the most simple 30 mins job. I have to say, I have never comes across the level of corrosion in any of the cars I have worked on. Sure one or two bolts or studs shear off, but I am not joking when I say almost all did or the level or corrosion made the threads useless. As an example the rear sub frame and the anti roll bar mounts. All four snapped needed two new sub frames. Anyway, rambling again, so back on topic. Once gearbox, exhaust was out, it was time to attack the engine. I followed all the great info from Pelican and the great videos in youtube and got the engine onto the hydraulic trolley and lowered in about 2 hours of total time (with lots of breaks, swearing and looking things up in between. On thing I will say is that I spend hours researching before I start. Easily into the hundreds so here we go http://986forum.com/forums/uploads02...1637181455.jpg Engine on trolley http://986forum.com/forums/uploads02...1637181500.jpg Ok, hit a slight problem, I couldn't get the car high enough as in the UK we have tiny boxes as garages. Dont get me wrong, mine is a double but the height is made for mini me's. http://986forum.com/forums/uploads02...1637181642.jpg So the engine was stuck in the drive shafts, raised the car to the highest I could and I was still hitting the rear sub frame so it came out. Quick check from the top and yes forgot return fuel line http://986forum.com/forums/uploads02...1637181705.jpg And finally, engine is out http://986forum.com/forums/uploads02...1637181746.jpg |
Straight in striping the engine attachments
http://986forum.com/forums/uploads02...1637181858.jpg And yes he is watching netflix as he works, we use the TV to looks at videos on YouTube but hey, he is 11 :) and hour later engine stripped and items labelled bagged, though I will replace all that is not already new with new as much as possible, especially sensors http://986forum.com/forums/uploads02...1637181975.jpg Next time to strip off the covers, cams and heads. This is where the fun begins :D |
Thanks for the posts. I love this stuff. It's always nice to see how others do things and by the looks of the way that rear end was rebuilt, you take your time and do it right. Please continue to share your journey.
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Great posts and even more special as you're doing it with your son! Please keep updating us as you progress, I'll be following.
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Thank you to you both.
Lots more to come as i believe it will help many by sharing the hows but also the “What the Fanta” moments Have you ever started something you felt would be easy and then wished you never had opened the swimming pool full of worms through no fault whatsoever due to you. :) BTW, in case I didn’t say, this car is a 2001 S with full Porsche service history with 3 previous owners inc me. The first owner had the car up to 67,000 miles over 16 years I had budgeted £2k - £4K for the engine rebuild depending on what shape the cylinders and pistons where in. More to come tomorrow :) and thanks again for the words of encouragement |
Fantastic journey you have started with your son. We have a same reason I purchaesd the Boxster 2,5 years ago - my son is now 15 yrs and is exited to tinker with boxter and to collect memories together and to learn of the car:cheers:
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What a great post, I will definitely enjoy following this!
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With the engine on a stand, next we locked the cams down and removed the covers.
So far, nothing looks too bad, chains have seen better days but cams and lobes look ok. Of course I need to take measurements but no real scoring http://986forum.com/forums/uploads02...1637232614.jpg http://986forum.com/forums/uploads02...1637232655.jpg |
with the cams out, we had a closer look
http://986forum.com/forums/uploads02...1637232803.jpg http://986forum.com/forums/uploads02...1637232828.jpg http://986forum.com/forums/uploads02...1637232847.jpg Some scoring on the carrier but not too worrying |
So what about the chain guide rails
http://986forum.com/forums/uploads02...1637233019.jpg Some grooving but expected worse and then found worse http://986forum.com/forums/uploads02...1637233066.jpg http://986forum.com/forums/uploads02...1637233099.jpg wow, chunks missing. As the car has only 70k on it and full service history, what plastic was used here. looking at this, they should have been changed 10,000s of miles ago |
oh, btw this is what I used to compress the tensioner, Much cheaper than the porsche tool and worked perfectly
http://986forum.com/forums/uploads02...1637233432.jpg |
When stripping down the hydraulic tensioners, one thing I found was the amount of gunk on the pistons. it did not slide easily. Also there was some seriously black oil inside it. I have only done about 800 miles on the car and had done 3 full oil changes, two when I first got it about 300 miles apart, and another when I did the IMS
When I drained the sump the oil was clean but the oil that came out of the tensioner was black so the question is why. I can only think that the it is primed but oil does really flow through it. In any case after I cleaned the tensioner with paraffin as to not kill the seals in side it now slides smoothly. Of course I will be changing the guides for new ones and going to test the solenoid on the bench BTW, important to know which tensioner is which as they have different solenoids. I bag everything in re-sealable sandwich bags that I label and only ever work with one bag at a time as to not mix things up I'll take some photos to share when I strip and clean the second one |
next up the lifters and their guides.
Loads of the lifters gunked up AND were stuck and took some effort to get them to move, once they did the same black but very stinking oil came out. I was able to polish them up and get them moving freely even when primed but I have decided to replace all of them with new http://986forum.com/forums/uploads02...1637237966.jpg carrier was in good condition though the guides were a little gunked up but they have cleaned up nice and the guides polished out http://986forum.com/forums/uploads02...1637238115.jpg |
next we needed to get the manifolds off but I was dreading this as the bolts were rusted to the point the no longer had a hex head. Totally soaked them in Kroil applying it 2-3 times a day over 2 days and used heat, but snap. snap. snap 4-5 bolts each side snapped.
Manged to get a few more out with a stud extractor but will need to drill and tap out the others. http://986forum.com/forums/uploads02...1637238470.jpg |
Time for the heads to come off and see what the bores look like (gulp)
Heads, not too bad on bank 1 http://986forum.com/forums/uploads02...1637238595.jpg and we can now see the pistons and bores and the pistons were caked in burnt oil, grud and ***te http://986forum.com/forums/uploads02...1637239046.jpg http://986forum.com/forums/uploads02...1637239077.jpg http://986forum.com/forums/uploads02...1637239103.jpg The bores, the ones I could see didnt look to bad at all, no scoring visible and felt smooth to the touch http://986forum.com/forums/uploads02...1637239189.jpg |
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Here is an example of the suspension and brakes completely rebuilt with new (apart from callipers which I refurbed) http://986forum.com/forums/uploads02...1637250012.jpg http://986forum.com/forums/uploads02...1637250045.jpg |
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.
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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 |
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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.
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Great thread!
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: http://986forum.com/forums/uploads02...1637291506.jpg this one was taken right after I removed the first bank cover, had not removed anything yet. http://986forum.com/forums/uploads02...1637291786.jpg 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 :). |
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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 :)
http://986forum.com/forums/uploads02...1637292833.jpg 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. |
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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. http://986forum.com/forums/uploads02...1637334211.jpg http://986forum.com/forums/uploads02...1637334232.jpg http://986forum.com/forums/uploads02...1637334250.jpg 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 |
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http://986forum.com/forums/uploads02...1637334794.jpg http://986forum.com/forums/uploads02...1637334824.jpg http://986forum.com/forums/uploads02...1637334854.jpg 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 :) http://986forum.com/forums/uploads02...1637334905.jpg http://986forum.com/forums/uploads02...1637334939.jpg http://986forum.com/forums/uploads02...1637334960.jpg I removed all plastics on the dash, doors, etc and gave them the same treatment http://986forum.com/forums/uploads02...1637335020.jpg 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 :) http://986forum.com/forums/uploads02...1637335166.jpg |
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also did similar to things like gear stick
http://986forum.com/forums/uploads02...1637335537.jpg http://986forum.com/forums/uploads02...1637335562.jpg |
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thanks for the heads up, very valuable info |
So next up is splitting the two halves of the bottom end. First remove the sump and all looks ok, yellowing at the cylinders as expected but all looked ok.
http://986forum.com/forums/uploads02...1637338118.jpg Ah, tiny piece of black plastic on the filter http://986forum.com/forums/uploads02...1637338166.jpg the more we go into the strip down the more I believe there is an oil way blockage or restriction due to debris. Will explain in later posts |
So one thing to share with anyone who is thinking of doing a rebuild, no matter how much you think you have drained the oil, you havent and loads more than you ever expected will continue to come out.
When I removed the oil level sensor over 500ml, which I was able to catch after it went over me, my son, the floor, the engine stand, basically everywhere of the darkest, smelliest, blackest oil came out Left is the oil when I drained the engine and right is the oil that came out of the oil level sender hole and it stinks, not just of fuel, but something else I cannot figure out. Dont have smellavision unfortunately :) http://986forum.com/forums/uploads02...1637339932.jpg http://986forum.com/forums/uploads02...1637339959.jpg |
After a million screws and gentle prying I got the first half off and could see the bores totally an the pistons and wow...
http://986forum.com/forums/uploads02...1637340232.jpg http://986forum.com/forums/uploads02...1637340267.jpg Totally crud all over them. I suspect valve stems were leaking but also rings where stuck on two of three especially the bottom control ring. other rings looked far too big as the gap was huge Luckily the pistons cleaned up nice http://986forum.com/forums/uploads02...1637340316.jpg http://986forum.com/forums/uploads02...1637340345.jpg Bank 2's pistons were in no better shape http://986forum.com/forums/uploads02...1637340380.jpg |
When I first looked into the bores, I totally bricked it as OMG, is that a crack in the walls?????!!!!!!!!
http://986forum.com/forums/uploads02...1637340507.jpg http://986forum.com/forums/uploads02...1637340540.jpg Luckily my son was not around as the amount of swearing that ensued was significant. Those observant amongst you may pick up on what I then realised, the mark is only where I had cleaned directly above is with some carb cleaner, luckily it was only a dirt mark :) But it did totally throw me for a while. I will check the cylinders once parts come back from cleaning and if there are cracks or oval'ing then I will have the cylinders replaced |
What did you use to clean up those pistons? I've got one souvenir piston from my engine before it was rebuilt. It's still on my workbench as it looks like your pistons before you cleaned them up. If I can get my old piston that clean, it will go from my workbench to my desk!
Are you going to check the cylinder bores for roundness, i.e., no ovalization? Everything looks great! |
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http://986forum.com/forums/uploads02...1637408600.jpg Then soda blasted at 50 psi then 30 psi http://986forum.com/forums/uploads02...1637408635.jpg They went back into the ultrasonic bath at 30 deg C wit a very mild carb ultrasonic cleaner and they came up like below. http://986forum.com/forums/uploads02...1637408823.jpg I did start polishing them up with some autosol and a rotary felt pad and then read they are coated so didnt want to polish out the coating. Got into a panic at first as though I had to buy a whole new set of pistons (and still might do mind you) but from what I read they are alloy with an iron coating, so used a weak earth magnet to test the coating is still there and it was on crown and skirts as this weak little magnet was very happy staying on the pistons Yes, once the casing are cleaned up I will check for roundness and magnaflux test for cracks. I prefer to work with clean components :) http://986forum.com/forums/uploads02...1637408943.jpg casings need a good clean first as does everything else too :) |
Ok, onto the home straight. At this point I have only the crank box and bank 2 on the engine stand.
BTW, before this point I realised I had the engine stand mounted across the two halves so I put the engine on the hoist, re-adjusted the stand so it would only be on bank 2 and then removed the bank 1 side. Forgot to mention this, so would have been far less hassle to get it right first. http://986forum.com/forums/uploads02...1637607100.jpg So removed the end caps from pistons 4-6 and dropped them out carefully. then removed the last long bolt on the Bank 2 side, hooked up the engine hoist to four points on the crank box, lots of prayers and gentle coaxing and the crank box separated from the bank 2 half. Lifted up the crank box (with brown pants) and then set down on a trolley http://986forum.com/forums/uploads02...1637607215.jpg Had a look into bank 2 half and looked ok, but wait...what the fanta is that in the top left corner, yep a nut, some rando nut, which looks like its been in there a while and defo not looking like its within the engine. I count everything I take off an bag it, so it is possible I dropped something while disassembly but very unlikely. http://986forum.com/forums/uploads02...1637607371.jpg Next split the crankcase, very carefully. Its not really heavy but awkward shaped. Looking at crank journals and bearings, they were not too bad but not far off end of life. http://986forum.com/forums/uploads02...1637607483.jpg I will need to take loads of measurements to check the crank to be sure but I was optimistic, then I reviewed my photos and my heart sank. http://986forum.com/forums/uploads02...1637607676.jpg What are those marks, they looks like metal that has been stripped away!!!!! At this point it was late one night, I had just tested positive for covid and I thought sod that, if the crank is gone this car will be parted out, cannot justify an 5k cost on a new crank. |
Fortunately the next day and in the sun, with a better photo I could see it was staining which was coming off with cleaning. The sprocket looked ok apart from some marking from the chain
http://986forum.com/forums/uploads02...1637607851.jpg Anyone know what is and is not acceptable here? Can the sprocket be rebuilt or would the crank lose its heat treat if it was? |
Ok, parts all stripped down and bagged or waiting for cleaning.
I am going to look to get the crank box rebuilt first once I have taken measurements and polished. Aiming to complete this by Christmas. At the same time I will send the cases, sump and some other parts from the bottom end to be cleaned Here is what I have ordered for this part of the rebuild Oil Separator (99610101000) Main Crankshaft Bearing Shell Standard. Porsche 986 Boxster / 996 >>2001 (99610120510) 2 x thrust washer (99610112952) 6 x splash valve (99610101851) Tensioner Blade. Porsche 996 1998-05 / Boxster / Cayman (99610516555) Tensioner Blade. Porsche 996 1998-05 / Boxster / Cayman (99610516651) 6 x pan-head screw M 6 X 16 (99921800501) Timing Chain. Porsche 996 / 986 / 987C / 997.1 (99610517158) 2 x Timing chain. Porsche 996 / 986 Boxster (99610517753) roll pin 6,0 X 16 (90009503101) straight pin A 4,0 X 10 (90030202100) 14 x screw M 9 X 127 (99610111559) |
Recap of what I did so far.
Remove rear bumper - Lots of great posts on this forum how to do this and YouTube videos Remove roof (easier access) - Lots of great posts on this forum how to do this and YouTube videos Remove Exhaust - Lots of great posts on this forum how to do this and YouTube videos, 101 projects, etc Remove gearbox - Lots of great posts on this forum how to do this and YouTube videos, 101 projects, workshop manuals, etc Remove engine - Lots of great posts on this forum how to do this and YouTube videos, 101 projects, workshop manuals, etc With all the resources online, dropping the engine is not as daunting as first thought with the bike lift and going slow and checking and double checking it came out with little stress. It took about 3-4 hours start to finish. That all said, the caveat to this is that I have already taken the gearbox off so all those seized and rusted nuts, bolts etc had already snapped and I went through the stress and time previously. As an example, I was going to reuse the original cats, but the flange bolts refused to come out and I had to sacrifice the cats to get them off. With Hindsight, if you want to reuse many of the items then plan for extra time to deal with the poor quality fasteners. If you plan to replace, then do what's most time effective :) If there is anything specific someone would like to know then please do ask Here are some of the tools I used
http://986forum.com/forums/uploads02...1637671314.jpg http://986forum.com/forums/uploads02...1637671331.jpg http://986forum.com/forums/uploads02...1637671349.jpg |
As part of the tear down, I am cleaning many components which I wont be replacing. Once of these are the Variocam adjusters. So I have searched the net looking for info on there magical devices and some does exist, but there is not much that shows some of the internals. Understandably so when we consider the cost of these. There also seems to be no way to refurbish them.
I had originally used paraffin on one of the adjusters and a ultrasonic bath to clean it and I thought it cam our well. When I went to do the bank 2 adjuster I actually saw some of the brown plastic from the guides in the same bag, which there should have not been any. On closer inspection and through some dismantling I found more fragments, some even blocking the holes on the piston visible. So I decided to take the risk and dismantle these and use a ultrasonic sensitive detergent at around 45 deg C and totally flush out the parts. So here is a caveat, I do not recommend repeating this experiment as at this time I do not know if it will fix or damage the part. I am only sharing what I did and my observations and not recommending the following to anyone to repeat. Each bank has differences, not only in the solenoid but also in the unit itself. Bank 2 has extra holes which oil is pushed through that bank 1 doesn't, also more importantly, there is a oilway at the top of bank 2 and this is on the bottom of bank 1 Below are some photos after the units were cleaned. http://986forum.com/forums/uploads02...1638115645.jpg http://986forum.com/forums/uploads02...1638115669.jpg http://986forum.com/forums/uploads02...1638115687.jpg http://986forum.com/forums/uploads02...1638115706.jpg Apart from the difference in part number stamped on each unit, there is a stamp indicating which cylinder it is intended for visible on the top of each unit next to the solenoid So how I cleaned the units was to dismantle each one, one by one as not not mix up the internals. Below are the internals for Bank 1 http://986forum.com/forums/uploads02...1638115864.jpg http://986forum.com/forums/uploads02...1638115902.jpg I next put the parts, not including the solenoid into an Ultrasonic bath with a sensitive detergent (metal and rubber) at 45 deg C for 10 minutes. I then gently moved the piston in an out (and I mean gently) and wow, the crud that came out and yes some more small pieces of plastic. On bank 1, there are only 3 or 4 places where fluid goes in and out so I just watched these as I GENTLY moved the piston. I then repeated the bath for another 10 mins and repeated GENTLY moving the piston and wow, even more crud and small pieces of plastic. Dont get me wrong, it was only 1-2 very small pieces but they were still there. Between each 10 min clean I rinsed in warm water, submerged and gently moved the piston. I repeated one more 10 min clean in the batch. I then polished the piston in the middle (below) and using a shoelace and oil only I polished the main piston in the unit. http://986forum.com/forums/uploads02...1638116258.jpg http://986forum.com/forums/uploads02...1638116283.jpg BTW, before cleaning the pistons did not move freely, either the one inside the main or the main. Following cleaning, I submerged the unit in fresh oil and gently moved the piston to prime it and removed as much water as possible. Yes there will be some water remaining but this will hopefully be removed when I break the engine in following the rebuild and the 2-3 oil changes I am planning post run in. The amount should be insignificant....hopefully :) |
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