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Joined: 24 Feb 2019
Posts: 165
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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Joined: 24 Feb 2019
Posts: 165
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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Watkins Glen

Joined: 08 Nov 2003
Posts: 2055
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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Joined: 24 Feb 2019
Posts: 165
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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Joined: 24 Feb 2019
Posts: 165
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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Joined: 24 Feb 2019
Posts: 165
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.


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Joined: 24 Feb 2019
Posts: 165
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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