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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Tue Oct 08, 2019 10:28 pm    Post subject: Reply with quote

Small update on this. While getting the rear brake line unions undone and ready for removal I realised that the crossover one to the OS rear wheel looks like a total nightmare to replace.

There are two pipe unions into the rear connector block (shock horror!) but the larger of the two (crossover pipe) , 13 mm is stuck fast so I am looking at options...and it's not a happy look. The corrosion is only in the 2 or 3 inches past the connector block and it's not overly bad now I scraped the paint off, but I thought seeing as I have it in bits I will replace them while the engine is out.

Well, I am deeply regretting that decision at this stage!; I know the stock steel pipes are not very flexible and it literally has to pass through some crazy places to make its way across to the OS rear wheel. Looks like all pipes have to be unbolted to stand a chance of fitting new oem one?

It literally seems to be the first thing that is fitted to the bare bodyshell.... dammit, the new lines are coming tomorrow so I will have to give it a go I think. Not good for my plans of getting the engine in this weekend! Also hoping the caliper bleed nipples undo , going to check them first!
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Fri Oct 11, 2019 8:44 am    Post subject: Reply with quote

Another update; well after confirming Porsche do not sell any connectors? (what's the all about then..!!) and would only sell me a new loom, the ebay shop I was directed to in my other thread happens to sell the connectors needed for the coils, 3 pin Bosch ones.

One connector was melted around the terminals, watch out for coil heatshields in bad condition as I think that was the root cause for this.

One coil connector just had a broken clip, that was an easy replacement (see pics removing its terminals using special porsche tool 0078 paperclip ), the other melted one I cut the connector off; then saw the terminals were a bit worse for wear after my exertions so decided to resolder new lead tails on. Additionally one of the wires had been hot as well so it was a non starter to use the old terminals on the new connector.


Now that is done the engine is built back up, just needs the engine hangar refitting and I will partly put the aux belt on to save a bit of time for when I have it back in.











Have new main rear brake pipes, the bleed nipples are all free on the calipers (first check I made) so although one nut is very stuck in the alloy block connector (at the rear NS of the car) I am going to have a go at getting it off this weekend and replace the brake lines and refit the motor. Will update
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2099
Location: Perthshire


PostPosted: Fri Oct 11, 2019 3:55 pm    Post subject: Reply with quote

All coming together now Thumb
_________________
2007 997 Turbo & 924s Restored
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Sat Oct 12, 2019 7:02 pm    Post subject: Reply with quote

Gazc2 wrote:
All coming together now Thumb

Cheers Gazc2 Thumb

Well, I stupidly decided to 'just' replace the rear hardlines before I refit the motor. I can confirm its a nasty job if you use the Porsche lines which I did. In reality my lines were in very good condition except for some surface corrosion near the joining block and a couple of little bits deep under the OS. But seeing as I had bought new lines, just in case... I had to fit them Very Happy

The short line (NS one) was a piece of cake. It came out of the connector block easily and was replaced easily. The large crossover line, not so much...
It was a pain on axle stands, a ramp would give a bit more wiggle room but I still think it would be a nasty and expensive job.

In the end I undid the OS rear top arm and that allowed me to get the brake line into place. At that stage it was all in the right orientation and near the correct clips so it was easy enough to clip it all up and fasten it from there. Getting it into the correct orientation was a bit like something out of the crystal maze.
The crossover line nut was well into the connector block so I cut the pipe, used a proper spanner and a little blast (very cautiously) of map gas to free it up, it came out in the end

A few pictures for posterity. Now that is out of the way, a few final prep jobs and checks and refit the motor as soon as I get chance. Also got read brake disc protectors to fit as the old ones have had it







 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Mon Nov 04, 2019 11:51 am    Post subject: Reply with quote

Small update on this. Have been busy with work and holiday but back with it now. I fitted the motor back in, connected the coolant pipes together and pressure tested the system with a coolant tank lid adapter and pump from the kit I bought.

All looked good, held pressure nicely. Then came out the next morning to find a small puddle of coolant under the car Surprised
Cue many swear words and taking the engine back out again (took 90 minutes this time as a lot wasnt connected) so I found the leak immediately and it was , as you might guess 'deep in' so I removed Bank one intake and tightened the offending jubilee clip (wasnt quite snug enough it seems!).

After that I decided to make a pressure test kit for the engine before refitting (which I duly did using a few plumbing skills and some bits from screwfix, 22mm copper pipe and end caps and a compressor shop supplied footpump connector and backing nuts). (will post a pic). I was very tempted to do this before the refit but thought I might get lucky... it seems not Hand

Pressure tested multiple times to 1 bar and now holds perfectly airtight for 15 minutes + so going to refit it once I have completed a few extra jobs I found!


1/ The studs for the exhaust heatshields are corroded and not full length anymore so not usable and machine screws were holding them on (fine). However I dont like bodges, so Im waiting for some nutserts and going to drill and sert them and need the engine out for this (not used them before but they look simple enough)

2/ while I wait for the nutserts and stainless bolts I am refurbing the lower suspension parts that are off the car

Hope to get the engine back in later this week and connected up and running asap
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Sat Nov 23, 2019 12:33 am    Post subject: Reply with quote

Well, got the engine back out again and in, pics attached of the pressure test kit I made. Refitted it last weekend and got a bit of time the last couple of nights to get it back together. Also pressure tested the system again and it held all night at 15psi which was expected but pleasing nonethless.

The underside of the car is back together, refurbed rear crossmember, ARB etc, new propshaft guibo.
Driveshafts on, fuel lines hooked up, few more bits to connect back up top, bleed the rear calipers, heatshields and exhaust on, intercoolers, liners, fluids (oil and coolant fill), then should be ready to prime it and start.







[/url]


 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Sat Nov 23, 2019 12:44 am    Post subject: Reply with quote

Oh, also fitted a new expansion tank as I spotted some micro cracking in the common area (one was almost full thickness) and a new coolant cap for good measure.
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Tue Dec 10, 2019 12:18 pm    Post subject: Reply with quote

Ok, time for an update. Not been a lot of time recently on this and I have been waiting on a few issues. Namely I found a leak/hole when I pressure tested an intercooler (like a pea sized hole in the core) so I have been trying to source replacement intercoolers without going to the OPC. After two sets of incorrectly fitting intercoolers, I ordered an OEM new one.

During the wait I stripped and had the intercooler cages repainted, and fitted new hardware. Also I now have the NS rear back together complete with a wheel! Hopefully the new IC turns up today or tomorrow so I can finish the other side and get it tested. Also got to add coolant, its been a bit late after work to run the compressor to get it vacuum filled, but it holds vaccum like a world champion!








 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Fri Dec 20, 2019 4:15 pm    Post subject: Reply with quote

Well, the car is back together and running sweetly I am happy to say. Will post a video at some point. Got to get the bumper on before I go chewing the tarmac but it runs sweetly; which is a nice little Christmas bonus!
Many thanks to Kozzi for the intercooler!!
Not sure if anyone else does this here for oil changes but I read best practice is to do a full drain, then put 2 litres down the oil filter centre, then the rest in the oil filler tube. I added 2 and 6 litres. Then pulled the fuel pump relay fuses x 2, let it turn over a bit, wait, turn over, wait etc until oil pressure built up.
Then fuses back in.
Car started first turn of the key and the mezger is purring, ready for some salty road driving action Surprised

Then added about just under half a litre of oil to get to max on the oil level display

Last edited by darkhorse on Sun Dec 22, 2019 12:33 pm; edited 1 time in total
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2099
Location: Perthshire


PostPosted: Fri Dec 20, 2019 6:49 pm    Post subject: Reply with quote

Good effort Thumb glad you got your various intercooler issues sorted all this hard work will be a distant memory once you get it on the road. look forward to your thoughts once you've driven it.
_________________
2007 997 Turbo & 924s Restored
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Fri Dec 20, 2019 7:07 pm    Post subject: Reply with quote

Gazc2 wrote:
Good effort Thumb glad you got your various intercooler issues sorted all this hard work will be a distant memory once you get it on the road. look forward to your thoughts once you've driven it.


Thanks Gazc2! Seems to be only you who diys their turbo from here..!
I do hope it becomes a distant memory, it has left a slightly bitter taste at present so its more relief that its done rather than happiness at this minute! Took it for a spin round the block earlier and it was like a rocket , boosting fully etc. Hoping it stops raining so I can take it out at the weekend for a full session as it were!
 
  
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Backday
Newbie


Joined: 01 Mar 2017
Posts: 5
Location: Sweden


PostPosted: Sat Dec 21, 2019 1:02 am    Post subject: Reply with quote

darkhorse wrote:
Gazc2 wrote:
Good effort Thumb glad you got your various intercooler issues sorted all this hard work will be a distant memory once you get it on the road. look forward to your thoughts once you've driven it.


Thanks Gazc2! Seems to be only you who diys their turbo from here..!
I do hope it becomes a distant memory, it has left a slightly bitter taste at present so its more relief that its done rather than happiness at this minute! Took it for a spin round the block earlier and it was like a rocket , boosting fully etc. Hoping it stops raining so I can take it out at the weekend for a full session as it were!

Very good effort. Me, I have a 2007 turbo and I have upgraded the turbos but I don`t know if I will dare to take out the engine when you must for some reparation. worship
 
  
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NickHappy
Nürburgring


Joined: 27 Apr 2014
Posts: 476
Location: W.Sussex


PostPosted: Sat Dec 21, 2019 7:17 am    Post subject: Reply with quote

Great work DH - been a great thread to watch Thumb I too am partial to a bit of DIY maintenance but doubt think I’d be able to work at the level you have here. Thank you for the updates - been greatly appreciated and this will be a decent diary to look back on.

I might look to swap my exhaust out early new year as a DIY project - I know where to come for some tips Very Happy
_________________
997 turbo Manual.
996 turbo Manual. ex.
 
  
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kozzi
Nürburgring


Joined: 30 Nov 2014
Posts: 476
Location: suffolk


PostPosted: Sun Dec 22, 2019 10:20 am    Post subject: Reply with quote

Glad the intercooler work DH!!!
Get her on the road now mate.
Just for information: had my turbo refurbed and hybrid by Turbo dynamics. One of them we though was shot by the have made them both like brand new.
Just in case anyone has been told by OPC or a specialist they are shot!
_________________
I am the beast that feeds the beast
 
  
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rabbitstew
Hockenheim


Joined: 21 Aug 2015
Posts: 728



PostPosted: Mon Dec 23, 2019 1:46 pm    Post subject: Reply with quote

Excellent work and glad it all is running smoothly. Always a very nervous moment turning the key after any major invasive work like this.

With regards to intercoolers, mines a 2008 and when I had the intercoolers upgraded to the do88 big pack I was surprised that the original intercoolers were beginning to rot through in places. I guess due to me using the car all year around ive thrown all sorts of weather at it. The front radiator consoles were also completely rotten through.
_________________
2008 997.1 Turbo Manual - 585whp thanks to do88 & 9e
 
  
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kozzi
Nürburgring


Joined: 30 Nov 2014
Posts: 476
Location: suffolk


PostPosted: Tue Dec 24, 2019 2:19 pm    Post subject: Reply with quote

Off topic - Rabbitstew what else besides the coolers have 9E done to get you the 585whp?
Thanks and Merry Christmas to all!
_________________
I am the beast that feeds the beast
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Thu Dec 26, 2019 11:17 pm    Post subject: Reply with quote

Thanks for the comments guys. Hopefully it will help someone else out who is in the sh*t with their turbo!!

Just waiting for the weather to pick up a little to go cruising, also got a headlight level sensor arm to fit, and a C203 steering wheel electronic control unit fault (PN 997.618.125.03), and also under Front body module - 8032 code - compression angle sensor front - PN 997 610 104 11

Not sure if the second one relates to my headlight level fix; will take it for a good drive as soon as its dry and update
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Tue Dec 31, 2019 3:47 pm    Post subject: Reply with quote

darkhorse wrote:
Thanks for the comments guys. Hopefully it will help someone else out who is in the sh*t with their turbo!!

Just waiting for the weather to pick up a little to go cruising, also got a headlight level sensor arm to fit, and a C203 steering wheel electronic control unit fault (PN 997.618.125.03), and also under Front body module - 8032 code - compression angle sensor front - PN 997 610 104 11

Not sure if the second one relates to my headlight level fix; will take it for a good drive as soon as its dry and update


Well, I fitted the new headlight levelling sensor arm assembly and went for a good drive with Durametric hooked up. After some googling it seems the PASM code can clear after a short drive. Happens after battery removal; and it did clear, I cleared other ones that lingered after the battery removal and I have a fault free car now on Durametric.. . All live data looks spot on. Just got to wait for some decent weather and go on some longer trips and see whats next!

Last edited by darkhorse on Tue Dec 31, 2019 5:27 pm; edited 1 time in total
 
  
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Backday
Newbie


Joined: 01 Mar 2017
Posts: 5
Location: Sweden


PostPosted: Tue Dec 31, 2019 5:14 pm    Post subject: Reply with quote

Great news. Now go and enjoy your " new" car Cool
 
  
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darkhorse
Monza


Joined: 24 Feb 2019
Posts: 201
Location: under the car


PostPosted: Tue Dec 31, 2019 5:31 pm    Post subject: Reply with quote

Backday wrote:
Great news. Now go and enjoy your " new" car Cool


Thanks Backday! Yes it will be nice to hopefully get some fun driving it now!
Got plans for a front end going over next, looks almost pleasant compared to all the other jobs I did . Want to check the front rads, maybe fit some mesh grill and a few other bits. Will update the thread
 
  
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