Cairo's Six - 3.6 in and running great! Options

[technicalninja]

Thanks for the aluminum foil tip on the 6/12 point internal stuff.

I'll try that from now on before cold chisel or Dremel cut off wheel solutions.

So simple!

I should have already know that!

Bad Ninja, Bad, Bad Ninja...

(IMG:style_emoticons/default/ninja.gif)

PS. The 911 looks interesting!
Include more pics of it if you can.
It looks as nice as your car...

[Cairo94507]

@technicalninja - Yeah that '74 is going to be real nice. It is Greg's and he has done it all - disassembly, stripping the shell, metal work, body work and paint. The motor is going to be an MFI motor of course. The interior will be next-level greatness too. I will start adding some photos of its progress as my car moves along. Greg is a very talented guy. (IMG:style_emoticons/default/beerchug.gif)

[Cairo94507]

Yesterday we started with Greg replacing the distributor belt. Now "they" tell you that you can drift the pin out for the gear at the bottom of the shaft; I call BS on that. We tried for a good 20 minutes and that little sucker would not budge. We ended up drilling it out and that did the trick with no collateral damage. I ordered a new pin from Porsche along with 2 rotors for general principle. So belt replaced and distributor reassembled- save for the pin which is on the way.

We then installed the oil return fitting below the oil filter on the 3.6 - took about 3 minutes- strangely satisfying though.

Then we installed the modified fan shroud "Mickey Mouse" ears and coil bracket with coils. I still have to order the new decals for the coils.

Greg did the modification that allows you to rotate the throttle body downward- that was a bit stressful just because we were cutting the plastic bridges (3) between the upper and lower. Glad to report that was done and now we can rotate the throttle body down about 1" or so to be sure we can clear the engine lid.

Then we pulled out ALL the wiring harnesses for this motor to go into the car. We have 2 PMS harnesses and then the stock 993 car harness that connected to the engine harness and DME (with 22 connectors). We already replaced the engine harness with a factory new harness- that was about $110= best deal ever. In total, It's a whole lot of wires and connectors. We are working to figure out exactly what we need and what can be discarded. That will be a big project.

We also got the PMS throttle cable on the engine- I just need to order the clip that connects it to the throttle body.

[ClayPerrine]

If I may make a suggestion:

Rewire the DME relay socket to use 2 standard Bosch square relays.

Original DME relay wiring diagram:



Modified to accept two square Bosch relays:



The reason I suggest this is that the factory DME relay is notorious for failing at the wrong times. It is considered standard procedure to carry a spare because they are only available from the dealer or specialty supply places. If you rewire the harness to use two Bosch square relays, you can get them at FLAPS and there are solid state relays available that almost never fail.

You can also use the round relay sockets the same way. Then you can borrow a relay from the headlights if your DME quits.

I did this on my 964 DME setup. It works great.

[Steve]

(IMG:style_emoticons/default/beerchug.gif) Looking good!! Almost there... Removing the ribs on the intake was stressful. I used tin snips for the center rib, since I couldn't get to it with my dremel tool. I was worried it would crack the tubes, but the tubes are pretty thick, so no problem. I also need to do the distributor drive belt. Thanks for sharing that procedure. There is also a nice write up for this on p-car and Pelican. https://p-car.com/diy/diy.html

[Cairo94507]

Thanks Clay and Steve.

Clay, I will share your thoughts with Greg regarding the relay wiring.

@Steve Yeah, we followed the Pelican DIY re the distributor belt. It was a very good step-by-step. I suggest your order a pin for the gear before you tackle the belt. The ignition distributor shaft gear pin part number is: Part #: 930-602-922-00-OEM. I believe I ordered it through Pelican.

Cheers,
Michael (IMG:style_emoticons/default/beerchug.gif)

[930cabman]

How could anyone estimate the hours, $$ involved in any of these conversions?

It's kinda crazy, really

BTW: looking great and I am sure the finish product will rock

[SirAndy]

How could anyone estimate the hours, $$ involved in any of these conversions?
It's kinda crazy, really
BTW: looking great and I am sure the finish product will rock

It was really simple.
I purposely did not add up any of the costs so in my head i'm still convinced i did the whole conversion for less than $10k.
(IMG:style_emoticons/default/biggrin.gif)

[930cabman]

How could anyone estimate the hours, $$ involved in any of these conversions?
It's kinda crazy, really
BTW: looking great and I am sure the finish product will rock

It was really simple.
I purposely did not add up any of the costs so in my head i'm still convinced i did the whole conversion for less than $10k.
(IMG:style_emoticons/default/biggrin.gif)

How many sane people would put themselves through this -------- you fill in the blanks (IMG:style_emoticons/default/happy11.gif)

[Cairo94507]

That's funny guys. Just the other day when we were working on it I looked at Greg and said, "What the F was I thinking? I had a perfect running 3.2 and decided to go through all of this? Greg laughed and agreed. He then said, "it's going to be bitchin' when finished". I sure hope so! (IMG:style_emoticons/default/beerchug.gif)

[930cabman]

Bitchin is good (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/smilie_pokal.gif)

[Gint]

OH, and for those "Porsche tax" followers, I was missing the small rubber "gasket" which fits into a slot on the outside of the cam chain box covers- straight piece of rubber with a channel that accepts the engine tin where it sits against the chain box cover. In Post 192, the last picture, shows the chain box cover with the engine tin slipped into the slot on the cover where the rubber gasket belongs. It actually looks like a wiper blade refill with a grove. I thought surely it would only be $10..... well $132 later I have those 2 small pieces of rubber coming from Porsche. That was with my PCA, AARP, AAA, Old Dude, and good customer discount.... man, Porsche, really?

Can I see what those rubber pieces looks like?

Looking great!

[Cairo94507]

Hi @Gint . Yeah, here is a picture of one side, they are identical.

[Cairo94507]

Didn't do much today. I did "install" the two stupid priced rubbers that the front engine tin fits into so it does not rattle and makes a good seal.

Then we installed the last piece of engine tin, the front (Fan) side- that completes the engine tins and I have to say they look great; Greg does nice work.

Then we began futzing around with the idle control valve that in its stock position sits right on top of the motor and looks like crap. So we are exploring relocating it under the intake or at the very least to the non-throttle side of the throttle body so it is not right in your face. We are going to source to 7/8" OD pipe and see if we can make a pipe that will allow us to move it. It pulls vacuum so a normal rubber hose would likely collapse.

Anyway, that was it for the day. We just kind of enjoyed lunch and then sat in the shade, like old men, and talked. (IMG:style_emoticons/default/beerchug.gif)

[Cairo94507]

More:

[ClayPerrine]

Nice air cleaner setup. But where is the Mass Airflow Sensor?

[Cairo94507]

@ClayPerrine - Now that is a great question (IMG:style_emoticons/default/confused24.gif) . The PMS boot which replaces the stock 993 boot has ports for "things". I doubt those are for the MAF sensor. I googled '95 993 3.6 Porsche MAF sensor and I don't think anything like that came with the engine as received. I will have to look into this on Tuesday when Greg and I next meet to work on this. And Clay, thanks for staying tuned in on this swap. I appreciate your expertise. (IMG:style_emoticons/default/smilie_pokal.gif)

[ClayPerrine]

@ClayPerrine - Now that is a great question (IMG:style_emoticons/default/confused24.gif) . The PMS boot which replaces the stock 993 boot has ports for "things". I doubt those are for the MAF sensor. I googled '95 993 3.6 Porsche MAF sensor and I don't think anything like that came with the engine as received. I will have to look into this on Tuesday when Greg and I next meet to work on this.

It isn't something that attaches to the ports for "things".

The MAF sensor goes between the air cleaner and the throttle body. It has to be there for the engine to run.

(IMG:http://www.914world.com/bbs2/uploads_offsite/cdn4.pelicanparts.com-1143-1715522456.1.jpg)

The factory motronic won't work without it unless you do major modifications to it.

[Cairo94507]

@ClayPerrine OK, that helps a lot. I will find one if we do not have it sitting somewhere. I checked the pictures I have of the engine as purchased and it did not have the MAF on it. I have reached out to the seller to see if it may be sitting around in his shop. Thanks again Clay. (IMG:style_emoticons/default/beerchug.gif)

[ClayPerrine]

@ClayPerrine OK, that helps a lot. I will find one if we do not have it sitting somewhere. I checked the pictures I have of the engine as purchased and it did not have the MAF on it. I have reached out to the seller to see if it may be sitting around in his shop. Thanks again Clay. (IMG:style_emoticons/default/beerchug.gif)

Probably still attached to the air filter assembly. And you don't need the air filter assembly, it won't fit in a 914. The DME harness should have a round plug that connects to it.

If you can't get the MAF, then you can buy one. They are about $200.00.

And you will need to hook the idle air motor in after the MAF.