Porsche 944 Rebuild
July 21st, 2009

Took the car in for its annual inspection today. No problems at all. They had some discussion on whether or not the license plate was legal by being where it was since it wasn't being lit by the under-the-trunk bulbs. But they put their heads together and saw the wires coming out of it and turned on the headlights. That put the end to that discussion.

However, on the way home I noticed that my odometer has stopped working sometime in the past week. I reset the tripmeter but that didn't free up whatever is binding it. I'll have to remove the steering wheel one of these weeks and take a look at it.

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May 24th, 2009

It wasn't from the gas tank this time. I turned the car on to a geyser of 93 octane Exxon coming from the fuel rail. Turns out, the o-ring that seated the fuel regulator to the fuel rail had split nearly in half. Apparently, it's the same o-ring used by the fuel injectors so a quick stop at NAPA for a fuel injector reseal kit saved the day.

fproring.jpg

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May 17th, 2009

Today:

  • Installed Air Conditioning compressor
  • Installed Alternator
  • Installed power steering belt
  • Installed primary belt
  • Installed Radiator (again). Had to correct the mounts. The original owner was an idiot.
  • Installed hoses.
  • Filled with coolant.
  • Filled power steering.
  • Looked over for anything missing.
  • Looked it over again.
  • And again...
  • Nervous...
  • And again...
  • Turned the key....
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May 12th, 2009

Stopped into the local Advance Auto where I get all my local parts for a few things.

First, a tie rod end was needed on the driver's side as the old one had its rubber boot disintegrated by age.

Secondly, the upper radiator hose has gotten too close to the alternator once or twice and a nice slit has developed in the rubber. I stopped into AA to see if I could get a generic heater hose but they don't stock metric sizes. Also, due to its shape, what they did have was kinking and wouldn't work. Turns out the hose is only $19.99 + $1 shipping. The bad news is that it'll take three days to get here. So I'm playing the waiting game.

Only a few things left to do. Attach the air conditioner compressor, the alternator, the upper radiator hose and fill 'er up with coolant and oil.

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May 11th, 2009

Another weekend, more progress:

  • Attached slave cylinder.
  • Attached starter.
  • Attached steering shaft to steering rack after fighting with it for an hour.
  • Tried to install the air condition condenser, but it wouldn't go back in so I gave up on that.
  • Fabricated some radiator mounts.
  • Installed the radiator.
  • Installed the radiator hoses.
  • Installed the speed and reference sensors.
  • Reattached all the vacuum lines.
  • Attached the sensor wires. To do this I had to remove the entire intake again.
  • Installed the power steering pump and hoses.
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May 6th, 2009

Spent the night transplanting all the remaining parts from the old engine onto the new one and starting the reattachment procedure.

newengineready4.jpg

Many pictures inside.

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May 3rd, 2009

The engine has been stripped of the red overspray as much as possible with paint thinner. But I will be taking a brush and some paint remover to it once it's installed in the car, as much of it won't be seen anyway.

newengineready1.jpg

Keep reading for more pictures and what I've done.

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April 27th, 2009

We've been attending the Porsche Swap Meet every April since 2007. The weather's been nice every year (apparently against tradition). Last year, I headed down looking for a new front valence for the 944. This year, due to a catastrophic engine failure, I went to purchase a new engine from another Porsche enthusiast. (More to come later on the engine failure).

Continue reading another video and a slideshow from the event.

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