911 Crew Cab Engine Page
Short history on the engine. The original 911 engine in the Crew Cab blew up. It dropped a couple of valves due to a leaky vacuum pipe running up to the brake booster. This happened in 1996, I was broke, the kids needed shoes, yada yada yada. I ended up storing it for 11 years.
In September 2007, a friend contacted me saying that he had been run off the freeway in his 911 by a big rig. At first he was interested in finding another body to rebuild his. But in a few short few months he realized that it wasn't going to happen. After some negotiations, we struck a deal on his 2.2 engine and his later model 901 5-speed gearbox.
This is what the engine looked like when I got home with it. It took 3 of us to put the engine and trans into the Syncro, boy was it a pain. Of course there is no one at home to help me with it, so I had to weasle it out myself. I did get lucky though. It turns out that once the engine stand bracket is on, the engine stands slides on perfectly! I guess that lift kit and big tires on the Syncro were just right!
Good thing I have an HD engine stand. One of those cheapy ones the VW FLAPS sell would fold up like a pretzel with this monster on it.
Of course he said it had just been serviced! Looks pretty oily, dusty, and greasy. He did give me a file that was about 1-1/2" thick of receipts for work done. Much of the older work was done by a good friend of mine. We started working on Porsches about the same time in 1985.
Porsches can be just as bad (or worse) when it comes to oil leaks. These engines have more gaskets to leak. There's also 4 valve cover gaskets with about 40 8mm nuts and crush washers.
I removed the timing chain covers and housings. Some of the surfaces had to be filed down so they would seal correctly.
The oil cooler was also leaking. It had a different fitting on it for the feed hose, so it needed to be switched out anyway.
The flywheel that came on the new motor was also the wrong type. This one was set up for the push type clutch, whereas mine still has the older pull clutch like a VW.
Here's a view from the top. The PO had installed a hatch in the truck bed. It is a complete hack job that I will replace along the way. I haven't decided if it will have a hatch or not. If so, I will put in a Vanagon stye engine cover.
This is a bad shot of the oil tank. It is a custom made aluminum unit and has the filter mounted to it. It also has a fairly nice oil filler tube that sits just inside the decklid. There are 2 breather hoses coming off the top that vent out the crankcase pressure. In this shot you can also see the support brace that was installed from the lower frame rail to the bed rail.
More to come. . .