Happy New Year to you too, Colin, and the rest of the Dorki family.

Today I started out by replacing the oil cooler (warmer) o-rings, cleaning it, and installing it.

http://i983.photobucket.com/albums/a...psfm7jliff.jpg
http://i983.photobucket.com/albums/a...psopej46bi.jpg

Then, I started cleaning bank 1 components. First up was the valve tappet housing. Dirty.

http://i983.photobucket.com/albums/a...ps4nkpepik.jpg

Better.

http://i983.photobucket.com/albums/a...psc8r7kdfo.jpg

Then I moved on to the valve cover. Dirty.

http://i983.photobucket.com/albums/a...pspfjyxhqy.jpg

Better.

http://i983.photobucket.com/albums/a...psmtd2fz9o.jpg
http://i983.photobucket.com/albums/a...psmx0vfwnl.jpg

Last thing today, I tackled the head. I forgot to take before photos, but I can show that on bank 2. Here it is cleaned up.

http://i983.photobucket.com/albums/a...psfid9o9cw.jpg
http://i983.photobucket.com/albums/a...psdh1qj36n.jpg

Valves are a little cleaner too.

http://i983.photobucket.com/albums/a...pssjh6wqac.jpg

Finally, I decided to check the valve seal on the head by filling the head with some ChemDip. It looks like a perfect seal to me. The hope is that the ChemDip will help with the carbon deposits as well.

http://i983.photobucket.com/albums/a...ps8mpobcgt.jpg

All said and done, this took 8 hours. I am hoping to repeat this entire process for bank 2 this weekend. After that, I can get busy installing the heads.

Tonight I finished cleaning the bank 1 head. I was able to clean the intake valves, but the exhaust valves have deposits that seem to be as hard as diamond. There may be a business opportunity there for me...

Anyway, here is the finished product.

http://i983.photobucket.com/albums/a...psxizx2cre.jpg
http://i983.photobucket.com/albums/a...psnabhtdre.jpg

As promised, here is what the bank 2 head looks like before cleaning.

http://i983.photobucket.com/albums/a...psa5wjs9mc.jpg
http://i983.photobucket.com/albums/a...psx0pwdaph.jpg

The plan is to clean all bank 2 components tomorrow.

Good Work
 

Mihnea,
You are rolling right along. Have you thought about having your injectors cleaned? I continue to be obsessed with the source of all the carbon build up on your pistons. One of the members on 986 Forum told me about RC Fuel Injectors. They clean and flow check your injectors for way less than new injectors.

When you clean the larger engine pieces are you using a parts cleaner machine or tub?

How were you able to install the RMS and the pulley seal? Did you use the Porsche tools or a substitute? I could see some PVC adapters being pressed into service. I noticed that Samstag sells the RMS tool for about $275 while Suncoast is asking $336. Maybe you can borrow them.

Regards,

Rob

Rob - I actually already had the pistons professionally cleaned and serviced a couple years ago. They also calibrated the jets, but it seemed that the pistons were performing all right even before the service. These services usually send you some printouts indicating before and after performance. Mine were improved by the cleaning and calibration process, but they weren't too out of whack to begin with.

I don't have a parts cleaner on hand due to the limited space in my garage, so cleaning the parts (large and small) has been a struggle. I've been using various plastic bins, metal trays, etc.

I haven't yet installed the front pulley seal or the RMS. In the past, I replaced these using the trusted PVC adapter method. I use a rubber mallet to slowly push the seal in, moving around the perimeter and I use a digital caliper to measure how far it's gone on all sides. Porsche recommends using their tool, which drives the seal in to an exact - predetermined depth. In my case, I like to vary the depth because there end up being some wear marks on the crank, so that same exact area may not seal as well anymore.

Ion came over today and we made some good progress together. We started off by cleaning all bank 2 components. Then, we moved on to cleaning the old head bolts. There are two different metal grades for the OEM head bolts. The lower grade requires replacement, the higher grade (found on later engines) can be reused. In my case, I had the higher grade bolts and opted to reuse them. Here they are all cleaned up.

http://i983.photobucket.com/albums/a...psulwulyj8.jpg
http://i983.photobucket.com/albums/a...psmwjzofwx.jpg

Here is all the bank 2 hardware before being cleaned.

http://i983.photobucket.com/albums/a...pspowh2tqh.jpg

The engine ready to receive the cylinder 4 -6 head.

http://i983.photobucket.com/albums/a...pshwxqgnyf.jpg

Head gasket on.

http://i983.photobucket.com/albums/a...psgpzskx0d.jpg

Cylinder head on.

http://i983.photobucket.com/albums/a...ps0jxdgsdy.jpg

Head bolts in and torqued.

http://i983.photobucket.com/albums/a...psmxc41agg.jpg
http://i983.photobucket.com/albums/a...psw9ztozdr.jpg

Block getting bigger. Getting there.

http://i983.photobucket.com/albums/a...psfsla98cp.jpg

Valve tappet guide installed.

http://i983.photobucket.com/albums/a...ps0gtymgr5.jpg

AOS vent line chuck attached, camshaft position sensor installed, and a cable harness bracket also installed.

http://i983.photobucket.com/albums/a...psoh0cckxu.jpg

Time to repeat the process on bank 1.

http://i983.photobucket.com/albums/a...ps7pgdj97n.jpg
http://i983.photobucket.com/albums/a...psjrhwrcin.jpg
http://i983.photobucket.com/albums/a...pslnwubviv.jpg
http://i983.photobucket.com/albums/a...psvprq0geq.jpg

Finished product for tonight.

http://i983.photobucket.com/albums/a...psjthphmuy.jpg

What are you going to do with all that free shelf space? Lol. Well done!

Wow! It's really starting to look like and engine.

Are you sure you're doing that right? :p

I'm going to have to take down the shelves in order to drive the car out of the garage. Space is tight.

No.

These photos are really nice, keep 'em coming!