924Board.org

[Leonov]

Long story short i am trying to replace my siezed up engine with a new(er) Rebuilt engine for my Porsche 924 Turbo. Does anyone know how to pull an engine (through the top preferibly but can do it through the bottom) And then replace it with the new one ( through the top or out the bottom respectivly).

[Rasta Monsta]

Um. . .yes?
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Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[BionicBalls]

[ideola]

Off the top of my head:

Drain oil. Drain coolant.

Remove the radiator and fan, along with all of the front-of-engine hoses.

Remove the AFM+Fuel Distributor assembly (stuff a rag in the turbo inlet).

Remove the oil cooler (three bolts at the fender and two banjo bolts at the oil filter console)

Remove the wastegate, the dump pipe, and unbolt the main exhaust pipe from the turbine housing.

Remove the air-oil separator and its drain line to the oil pan.

Remove the starter. Remove the clutch slave cylinder (might as well drain the brake fluid reservoir at this point).

Unbolt the four bolts that fasten the torque tube to the bell-housing.

Drop the front cross member.

Hook up hoist and ease the engine forward a little bit. Disconnect the heater hoses and all of the engine harness connections.

You should now be able to pull the engine out the top with an engine hoist / crane / cherry picker (or whatever else they call them in your neck of the woods).
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erstwhile owner of just about every 924 variant ever made

[emoore924]

On a scale of 1-10, 10 being most difficult, this job is about a 9.5 IMHO. You need the right tools, the right place to do it, and teenie tiny arms and fingers that all bend in 4 different directions to get at some of the impossible-to-see-or-reach stuff. So don't underestimate the effort here. This ain't easy.

Alternative:

1) Find competent 924 mechanic. Coax him out of retirement.
2) Trick him into thinking this is as easy as a n/a
3) Drop car off to have engine removed, repairs made
4) Stop back about two months later after repairs are made and engine is back in.
5) Listen to him b*tch to high heaven for 45 minutes about how hard a job it was.
6) Write big check and thank him profusely for his troubles.
7) Thank your lucky stars you found someone else to do this work for you.

Job done.

[Grenadiers]

Yeah, even with my BenPak car lift, 1000# tranny lift, big-butt engine hoist, it's still in the details that drive you nuts.

I replaced a heater core in a 1998 Mitsubishi Eclipse last weekend for a friend. Dash removal, center console removal, etc. In comparison, I'd rather switch out the toofah motor.
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'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke

[SlayerSST]

--o

[ideola]

Why bother? The line attaches up top, and must be disconnected. There are only two 13mm bolts that hold the slave in place. You risk damage to the slave and the firewall by leaving it in place, and much easier to detatch the hardline once the slave isremoved from the bell housing.
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erstwhile owner of just about every 924 variant ever made

[924RACR]

I did actually leave my slave in the car - it's such a PITA to bleed, I preferred to leave it in there, and bolt in when I get the engine back in.

Actually, of course, now with the engine out will be a perfect time to flush/bleed it again... LOL

As an aside... just lapped my block in this past weekend, to improve the finish for the Cometic HG... interesting process. Will probably have to do the same to the head once I get it stripped down for refresh...
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

[ideola]

[tyfighter123]

Hey Vaughan do you have a "how to" on lapping your block?
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Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)

[924RACR]

Not really a DIY process - you need access to a lapping plate, big slotted slab of cast iron. See your local machine shop...
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype