928 S4 Engine Project

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14 Mar 2014 19:54 #16904 by 1989porsche928
Hi Everyone, I am going to do a 928 S4 Engine rebuild project. Basically I have purchased a 928 S4 bottom end engine off of ebay and will dissemble it and rebuilt it as well as some cylinder heads. I have never worked on internal engine parts before. I have not received the engine yet. I won the best offer for $250 and it cost another $230ish to get it shipped to my friends house.
Here are some of the pictures that were on the ebay add. It looks like it has some oxidation. I am trying to build a quality 928 S4 engine on a budget. Any suggestions? When I first get the block I want to dissemble it and clean it. The 928 Workshop manuals don't give to much instructions. Does any one know how much you can bore out the 928 S4 block?

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Also I am doing this in Hudson Valley, NY so if you guys don't have anything to do you can help me thanks

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17 Mar 2014 18:33 #16920 by 1989porsche928
Update: I got a phone call today, the engine should be delivered to my friends house tomorrow. I'll post some pictures of it.

What should I do to the pistons, rod, and crank? I want to keep it but I heard I should get the crankshaft cross drilled.
What do you guys think? What are your recommendations? Is it possible to modify the connecting rods and pistons so
it lubricates the engine better?

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19 Mar 2014 09:23 #16923 by wallyp
Replied by wallyp on topic 928 S4 Engine Project
That looks like serious corrosion - my first guess is that the engine was either underwater, or more likely, sat exposed to the weather for a long time. I'm afraid that you may have problems with rust on the internal parts...

Wally Plumley
928 Specialists
www.928gt.com

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20 Mar 2014 08:59 #16924 by MarkP
Replied by MarkP on topic 928 S4 Engine Project
Check out Jay Leno's Garage on youtube - search for nano lubrication. You'll see Archoil has a great rust solution - plus solutions to reduce engine wear and extend the life of gasoline while your car isn't being used/mitigate the negative effects of ethanol.

Also check out Jay's video on waterless engine coolant - this could, among other benefits, mean an end to changing the water pump at your next timing belt replacement since there will be zero corrosion. I'll be switching to this when I return to TX later this year.

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20 Mar 2014 21:48 #16925 by 1989porsche928
thanks for the information WallyP, I got the engine the other day, will post some pictures soon. I had to order some 12m 1.5 bolts from a website that sells random porsche tools like that so I could mount it on the engine stand. I will post some pictures of when it is on the engine stand.

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20 Mar 2014 22:07 #16927 by 1989porsche928
MarkP I plan on taking the engine apart the day I can get it on the engine stand. I will put the internal parts in a solvent tank to clean everything.

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22 Mar 2014 12:38 #16938 by mm928
Replied by mm928 on topic 928 S4 Engine Project
Or just sitting outside forever! Good luck, it will good to see if you can bring that up to spec eventually

1983 928S - 16v 4.7L L-Jetronic
Dark Grey w/ Blue Leather
85/86 exhaust manifolds
Y-Pipe
SS Hi-perf Cat
S4 springs
Bilstein shocks
Air pump delete
VIN: WP0JB0926DS861180
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22 Mar 2014 20:53 #16942 by 1989porsche928
thanks, i think the original photos from ebay were from a low quality camera. the engine does have some oxidation on the outside, it doesn't look that bad so far. I turned it upside down for a second a bunch of green coolant came out. I made today's goal of assembling the engine stand and putting the engine on the engine stand. me and a friend picked the engine up, it was not heavy at all, and another one slid the stand on it. I am waiting for the Jim Morehouse CDs to come in so I have a better idea of what I am doing.

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23 Mar 2014 05:37 #16946 by wallyp
Replied by wallyp on topic 928 S4 Engine Project
"I am waiting for the Jim Morehouse CDs to come in so I have a better idea of what I am doing."

Your best idea so far! That much reading will keep you off the street and out of trouble for awhile...

Wally Plumley
928 Specialists
www.928gt.com

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28 Mar 2014 23:29 #16975 by AirtekHVAC
Replied by AirtekHVAC on topic 928 S4 Engine Project
I don't think you can just bore out the cylinders....has something to do with the silicone impregnation ( is that a word? )...I'd post the questions on RL, for the experts to chime in...I just think I know stuff...

1978 5sp #30 - Rescue
1979 5sp - Rescue
1982 5sp. - Rescue

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29 Mar 2014 16:54 #16977 by 1989porsche928
Here is some pictures of it

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29 Mar 2014 16:56 #16978 by 1989porsche928
I am probably going to throw away the flywheel, it is not compatible with an '89 transmission.

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30 Mar 2014 09:18 #16981 by wallyp
Replied by wallyp on topic 928 S4 Engine Project
You never know which parts someone else will need...

Wally Plumley
928 Specialists
www.928gt.com

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30 Mar 2014 10:45 #16982 by 1989porsche928

You never know which parts someone else will need...


your right, ill post it for free once i take it off. i cut open my finger removing the starter bolts, for some reason the oil pan bolts came off very easy, some of them were hand tight.

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30 Mar 2014 16:14 #16986 by 1989porsche928
probably should have taken the flywheel off before putting the engine on the stand, now i have to take of engine off the stand and remove the flywheel

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07 Apr 2014 09:50 #17007 by 928mac
Replied by 928mac on topic 928 S4 Engine Project
Dont bore or let anyone hone the cylinders!
There is a special process. if there is no ridge then I would leave the cylinders.
check the process with greg brown on rennlist

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08 Apr 2014 19:48 #17017 by Normy1
Replied by Normy1 on topic 928 S4 Engine Project
Let me continue the good advice that Mac was giving:

First of all, that engine has been exposed to the elements. It is probably a decent core, but it needs a comprehensive OVERHAUL. Are you willing to spend the $8000 that it might take to bring this engine back to perfect condition?

Second: What are you going to do with it? Are you going to take it back to perfect to make the perfect '87 928S4? Are you going to supercharge it and build a monster? Are you going to mount it into a Model A Ford hot rod? Before we can give you any more advice you need to tell us what you are going to do with this project.

N!

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08 Apr 2014 20:09 #17018 by Normy1
Replied by Normy1 on topic 928 S4 Engine Project
By the way....How do you know it is an '87? Look up the casting number: It is near the front top of the engine, a square section to the left of the large round hole where the water goes in. It is obvious in your third picture-

My '85S2 has a number M28-21, with 519 below it. Your car should say M28-47, with your engine's serial number. According to people on that website that starts with R, the people in Stuttgart can pull up a card that tells all about the car this engine was built with. Including the exact person who built it.

N!

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08 Apr 2014 22:07 #17020 by 928mac
Replied by 928mac on topic 928 S4 Engine Project

by the way....how do you know it is an '87? Look up the casting number: It is near the front top of the engine, a square section to the left of the large round hole where the water goes in. It is obvious in your third picture-

my '85s2 has a number m28-21, with 519 below it. Your car should say m28-47, with your engine's serial number. According to people on that website that starts with r, the people in stuttgart can pull up a card that tells all about the car this engine was built with. Including the exact person who built it.

N!


lmao

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10 Apr 2014 17:49 #17028 by 1989porsche928
thanks for replying. I am taking the photos from my galaxy note 3 cell phone. Believe it or not the block is almost perfect (besides rusted flywheel). It does have alot of gunk on it. Almost anywhere on the block i can spray a little brake cleaner or grease remover and with a little elbow grease it is shiny again. I have not been able to work on the engine since last post. I busted my knuckle open removing the starter bolt, its almost better now. I will probably order the tool to remove the flywheel tonight. Right now my plan is to take the engine apart and clean it. Then I will inspect all the components. I am tempted to send off the crank to have it micropolished and chaffered.

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14 Apr 2014 23:30 #17045 by 928mac
Replied by 928mac on topic 928 S4 Engine Project
wire brush the flywheel. rust is not an issue

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17 Apr 2014 19:40 #17064 by 1989porsche928
928mac the flywheel is not compatible with an 89 they change the flywheels that year or the year before. I finally got the tool in from sears. it is a 12mm triple square bit. it looks very strong. Unfortunately it decided to get cold in NY again so I can't work on it today. I did notice a scratch so the engine will probably have to be bored or plated after i take it all apart. Have you guys seen anyone bore it alot and put in a sleeve or liner? I dont think it is impossible.

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19 Apr 2014 07:00 #17073 by wallyp
Replied by wallyp on topic 928 S4 Engine Project
"I did notice a scratch so the engine will probably have to be bored or plated..."

It would have to be a serious scar before I did anything to the cylinders.

Wally Plumley
928 Specialists
www.928gt.com

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19 Apr 2014 12:12 #17077 by 928mac
Replied by 928mac on topic 928 S4 Engine Project
I'm with Wally on this. can you get a good picture. It may be hard and sometimes with out a flash is better. There are guys in Cal LA that have made very successful over bores.
It is pricey though.
If you have an extra $30-40 grand I have seen 6L engines that look stock and deliver California emissions.

Lets start with I picture.

Brad

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10 May 2014 20:26 #17193 by 1989porsche928
Sorry for the delay, I took the engine apart and started cleaning it in a solvent tank (probably a lot weaker stuff that a car shop would use)

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