944 S2 Repair

[Waylander]

do you have a link or can you divulge where the tube bearings came from?

thanks

[sgl1966]

I used Wyh Bearings for 4 FAG x 6006-2Z-C3. There is discussions whether C4 is better with larger clearances or you can pay $500 for some of the "super" bearings from the states, but the old ones did 25 years ,so same again please.

[TonyKart]

Very nice project....where did you get the 968 style mirrors from????

[sgl1966]

Sorry that should have been Wych bearings, the c button is sticking. As for the mirrors, they came from 'Club Autosport', they dont fold and I would use an opc gasket, but huge weight saving. Does need you to modify the mirror holes in the door.

[sgl1966]

Just got my flywheel back from having it skimmed and the new clutch plate they made up for me. Went with sprung six puck, should be strong enough for the power upgrade and hopefully not to jerky on the road.

[sgl1966]

Drove back from from the garage with new mot !
Need to set up the suspension and get over to the rolling road to tune it. Very happy with how the project is turning out since starting with rust bucket I began with. Couple of photos from today compared to how it was 18 months ago.

[deLUX]

Lovely jubbly!

[sgl1966]

Due to this being an S2 even though we used a turbo engine loom the wiring for the tubocharger water pump is on the main car loom which wasnt changed. So as both turbos are watercooled it seemed silly not to try and wire this in. We stripped down the appropiate wires and connectors from a turbo loom and married them up to the S2 loom locating the relay in the correct position in the fuse box. Cant believe the weight of the wiring in these cars nor the amount of wires going to the fuse box.
Just need to wrap these wires and its all working.
Went up and down the road a few times and found the backend is stepping out as the boost comes in and when you lift off which is a bit unnerving. Car is booked in to Brookspeed next week to get a full geo set up. Anyone used them ?

[sgl1966]

Wet afternoon so decided to throw on the newly painted bonnet to see what it looked like. I think I like it, but it is done for a purpose so as long as it aids cooling and intercooler airflow it will be staying. I havn't alligned it properly yet, just wanted a look.

[sgl1966]

Spent the morning alligning the bonnet and fitting a new bonnet cable and adjusting the latch, then took her out for a couple of trips up the road. Not ideal conditions with the rain but gave her a few full throttle blasts in third and fourth which showed how quick this will be . Found the wastegate to be opening early so adjusted the boost but unfortunatly it stalled as we returned home. Turned out to be fouled plugs as I am running rich at the moment and running 3.5 bar fuel pressure. Cleaned the plugs and all ok. Ordered some cooler NGK plugs.
As an aside I bought a damaged 2.7 head a while back to have the inlet valves as spares, but I found a company that can repair it , so as i have a spare 3 litr crank some JE pistons and all the other parts needed bar some conrods, I purchased another block to get sleeved and start another engine build. This time will attempt a more extreme build with a larger more modern turbo.
Couple of photos showing new bonnet getting wet and a slightly worse for wear cylinder head.

[Greggers]

Wicked!!

[sgl1966]

Last time I took the car out it stalled at the end of the day, checked plugs and they were all fouled due to it running rich. Ordered some new colder plugs which i fitted sunday and car started but would not idle and die if given some throttle, then wouldnt start even though fuel pump working good fuel pressure, 12v at coil (both sides ?) but no spark. Changed coil,DME , diconnected alternator, checked continuity from ecu to coil,checked all the earths, removed wiring for turbo water pump in case we had disturbed something but still no go, got cold and gave up for the day !
Next step is to check reference sensors with a scope to check the wiring all good as the sensors themselves are brand new, when I am allowed out to the garage over christmas break. Ideas as to problem more than welcome.
I found the scoring in the block I bought was not that bad and as the pistons and rings (alusil compatible) I had are 104.5, Ian at the engineering shop reckons we will lose them with boring and honing so rather than liners will run just the Alusil in this engine. He has done a couple of aero engines running alusil in the past and knew all about the honing/polishing required, if people are willing to trust him at 10,000ft with thier engines thats good enough for me.
So while waiting for Ian to do the block, I started at the top and built up the cam tower after having it powder coated.

[woolie]

wow... nice work

[R/E 951]

Simon,
Sorry to hear about your problems I am also having a few lately.
Just to save you alot of unnecessary work if you are using Toms ECU (I think you are) then a bad reference or position sensor will show up as positional errors. Sorry I can't give you any other pointers as I now how annoying a problem like this can be.

Top work on the engine, your work looks very nice.

Are your pistons custom and if so did you get them through JE direct? Wanting to get a set made sometime soon.

Cheers
Robert

[sgl1966]

Thanks Robert, I was unaware of this as we have not had much of a chance to play around with the ecu, unfortunately I also found on sunday that I have managed to break off the USB port on the breakout box and am sending it back to Tom for repair, I can be slightly ham fisted with the more delicate electrical components, so will have to continue with a scope.
The pistons and rings were a lucky purchase from ebay but came through Lindsey Racing as can be seen on there web site. The guy selling them needed larger as his scoring was deeper.
From what I understand it is the rings that are the harder to source (104.5 no longer available from Porsche ) than the pistons as these can be made to whatever size from JE with a suitable surface coating to run in alusil. The rings for these are a set of Total Seal that require the top groove of the piston to be machined to fit the groove, again alusil compatible.
Good luck sorting your problems.
Simon