928 Engine

There are two kinds of 928s out there, ones that are well taken care of and those that are neglected. The neglected usually end up getting half-measure repairs and slip into the abyss. For me, I wanted to try a 928 but did not want to spend a lot of time "unfixing" a bunch of problems. I went looking for an unmolested car and eventually found this one.

The car was drivable but had a series of problems:

  • clutch pedal halfway to the floor.
  • serious exhaust leak.
  • Oil leaks
  • irregular idle during warm-up
  • all manner of interior problems

All of these symptoms are petty typical. So anyway, the exhaust leak was a special problem because there were a couple of broken studs on the heads. Sometimes a creative mechanic can change a broken stud with the engine in situ but on this car there just isn't much room to work with. Also I really wanted to get a peek at the inside of the engine. So, the engine pull started - that was in the spring of 2010.

Note the broken off exhaust stud, the nut is hanging by one thread. The main exhaust leak was down on the Y-pipe though.

Not sure what is up with all of this RTV, sealing the starter - learned later there should be a simple piece of foam to close this gap.

Engine pull under way. It really came out pretty easy. The clutch arrangement allows for a quick disconnect from the rest of the drive line and there's no debate about which way to lift - just straight up and out.

 

Note the use of ramps to get the car up. This really helps to quickly address problems during the engine pull. Geez, I would kill for a lift though.

Rat's nest number 1. The intake valley is a perfect gathering place for all kinds of debris.

Oil leak number 1.

Oil leak number 2.

Oil leak number 3

Desperately in need of a bath. Note the use of a jack to prevent stressing the torque tube and trans. Once the engine is clear, this support is not needed.

Breaking down the intake I find some obvious brittle plastic issues.

Fuel lines, hard as rocks.

The entire throttle body assembly is laying loose as all three of the mounting isolaters are broken. I think this contributes to vacuun issues between the throttle body and the AFM.

First look at cylinders, turns out they look pretty good. Also, note the TB isolator studs separated from the rubber portion and still attached in the valley.

Comparing this next pic to the first under-hood pics kinda tells the story of where this is going. The deeper I go, the dirtier it gets. A first look under the oilpan is a shocker. I'm thinking this car went very long periods between oil changes.

So, while I thinking about that, I move on to checking the crank end-play. More on it in the Block section.

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