Tag Archives: 911 Engine Rebuild

911 2.2S Engine Rebuild – Part 14: Dizzy, Aerated & Exhausted!

Plumbing almost complete
Plumbing almost complete

This could be the range of emotions that you’d expect to go through as an integral part of classic car ownership but in the context of this post they refer to remaining problems that had to be sorted out on my engine following its complete rebuild.

With the benefit of hindsight – driving the car to Le Mans in June 2014 before the engine was fully sorted and properly set-up  wasn’t one of my better ideas!

Connecting up reinstalled engine
Connecting up reinstalled engine

Steve did his best to sort things out but both he and I were unaware of some underlying issues which impacted performance and smooth running during the trip.

Thanks to Steve’s perseverance in analysing the multiple, linked issues and sorting them out I now have a car which is running so much better than on the Le Mans trip that I barely recognise it. I just can’t stop grinning whilst driving it!

Continue reading 911 2.2S Engine Rebuild – Part 14: Dizzy, Aerated & Exhausted!

911 2.2S Engine Rebuild – Part 13: 911 Repossession Completed!

Fri 28th Feb 2014

After the dyno running-in and set-up of the engine, Steve and I both thought  all we would have to do is insert the engine back in the car, connect everything up and away we go.

It didn’t quite work out that way, there were a few snags, but Steve and Dave thankfully sorted out the last few issues and I headed up to Wembley on a cold and wet Friday afternoon to pick up the car.

Continue reading 911 2.2S Engine Rebuild – Part 13: 911 Repossession Completed!

911 2.2S Engine Rebuild – Part 11: The Long Awaited Dyno Test

Tue 4th Feb 2014

I called Jaz on Mon 3rd Feb and got the great news that, at long last, my engine was being run-in on the dyno at BS Motorsport.

Earlier, Steve had temporarily given up on his fight to bore out the mis-matched 2.0L inlet manifold to 2.2S spec. However, through a fortunate and timely parts swap, he got hold of a proper matching 2.2S manifold to stick on the engine which enabled dyno testing  to go ahead.

Steve had delivered the finally complete engine to Neil Bainbridge (who heads-up BS Motorsport) a couple of weeks previously, but we had to wait patiently for Neil to return from his annual pilgrimage to Daytona and then for him to then catch up on a backlog of other engine jobs.

Inside the BS Motorsport dyno control booth - Neil Bainbridge at the helm
Inside the BS Motorsport dyno control booth – Neil Bainbridge at the helm

With running-in under way – I arranged to meet Steve at the dyno the following evening (Tue 4th Feb) to discuss the running-in results with him and Neil and to observe adjustments and further power runs to optimise engine set-up and performance.

Continue reading 911 2.2S Engine Rebuild – Part 11: The Long Awaited Dyno Test

911 2.2S Engine Rebuild Part 10 and three quarters – A Further Delay

Mon 18th Nov 2013

An email from Steve at Jaz explained the latest delay in getting my engine onto the dyno test cell for running in and fine adjustment.

When fitting the inlet manifolds, air boxes and air tubes onto the throttle bodies Steve noticed a difference in the diameter of the bores of one inlet manifold when compared to the other. Would you believe it? Two different inlet manifolds!!!

Continue reading 911 2.2S Engine Rebuild Part 10 and three quarters – A Further Delay

911 Restoration Story

Bodywork repairs near completion at Sportwagen
Bodywork repairs near completion at Sportwagen

So what exactly is my car?

It’s a RHD 911 2.2E Coupe manufactured in Oct 1970 and first registered through AFN in Isleworth in Jan 1971.

I acquired it as a “project” in 1997 along with new wings, supposedly rebuilt engine, re-trimmed (leather) seats and other parts through Peter Andrews (Transend) who’d been tasked with finding me a 2.2 or 2.4 early 911 Coupe.

The engine that came with the car was actually a 2.2T with Zenith carbs which turned out to have pulled head studs. I replaced it with a second hand period 2.2S unit acquired again through Transend. This came with its MFI and was running but with no information in terms of mileage. With the addition of SSI heat exchangers and initial set-up and maintenance by Jaz – the engine gave me 15 years service but it eventually received it’s long overdue rebuild at Jaz. The amount of engine work required shows how Porsche reliability can lead to them being their own worst enemy as engines will just keep on running even when they’re completely worn out.

911 2.2E
911 2.2E

The gearbox is an original 901 5 speed dogleg unit which provided a couple of years service before receiving an extremely necessary full rebuild by Steve at Jaz. Apart from the long reach – it’s a lovely gearbox to use with an unbelievably light clutch. Dogleg 1st initially took some getting used to but I haven’t reversed rapidly into anyone from a standing start yet!

The suspension that came with the car was a an odd coil-over set up rather than the original self levelling system used on the E model. This was replaced with a more conventional Bilstein set-up at the end of the racing season from one of Steve’s (Jaz) race cars. New vented brake discs were fitted and the standard front brake callipers were upgraded to the alloy S units. I wonder how many E’s still have the self-levelling Boge set-up?

The original colour of the car was Olive Green (colour code 3939) but even Bruce at Sportwagen who’s normally a stickler for returning cars to the same colour they left the factory agreed that Zitron Gelb was a much better alternative – still very 70’s but less offensive/an acquired-taste!

911 2.2E
911 2.2E

OK – so it’s not a matching numbers car but with the exception of a few necessary and/or sensible updates all of the modifications made to it are in line with those available at the time the car was new or nearly new.

The story in full…

Spark Life – Sat 23rd Sep 2017
911 2.2S Engine Rebuild – Part 14: Dizzy Aerated & Exhausted!
911 2.2S Engine Rebuild – Part 13: 911 Repossession Completed!
911 2.2S Engine Rebuild – Part 12: Car & Engine Reunited
911 2.2S Engine Rebuild – Part 11: The Long Awaited Dyno Test
911 2.2S Engine Rebuild – Part 10 and three quarters: Further Delays
911 2.2S Engine Rebuild – Part 10.5: Part 11 Coming Soon – Honest!
911 2.2S Engine Rebuild – Part 10: Almost Complete
911 2.2S Engine Rebuild – Part 9: Bottom End Built
911 2.2S Engine Rebuild – Part 8: Problem 148
911 2.2S Engine Rebuild – Part 7: Gentlemen Start (Rebuilding) Your Engines
911 2.2S Engine Rebuild – Part 6: The Bits Are Back In Town!
911 2.2S Engine Rebuild – Part 5: International Crankshaft Rescue (Thanks Steve)
911 2.2S Engine Rebuild – Part 4: Cream-Crackered Crank!!!
911 2.2S Engine Rebuild – Part 3: Where’s My Bloody Engine?
911 2.2S Engine Rebuild – Part 2: Let The Strip-Down Commence
911 2.2S Engine Rebuild – Part 1: Taking The Plunge
911 Bodywork Repairs at Sportwagen 2010
911 saga

911 2.2S Engine Rebuild – Part 10.5: Part 11 Coming Soon – Honest!

Wed 29th Oct 2013

Throttle Bodies Missing In Action

Where are my throttle bodies?
Where are my throttle bodies?

Sorry folks – I had hoped to be reporting back on the results from dyno testing today but Steve at Jaz has still not managed to retrieve the throttle bodies. It looks like the engineer working on them is missing presumed on half-term holidays.

The good news from Steve is that the fan is sorted and ready for him to pick up en route to BS Motorsport for the dyno test. He’ll fit it before plugging the engine into their test cell.

Continue reading 911 2.2S Engine Rebuild – Part 10.5: Part 11 Coming Soon – Honest!

911 2.2S Engine Rebuild – Part 10: Almost Complete

Fri 25th Oct 2013

Waiting for fan, throttle bodies & other bits and pieces
Waiting for fan, throttle bodies & other bits and pieces

Work prevented me from getting across to Jaz earlier but It was clear upon arrival that Dave had been a busy man. The engine was looking almost complete with heat exchangers, cam covers, timing chain covers, MFI fuel metering pump, engine tin ware, modified shroud etc. all attached. The quality of finish on each individual compent just takes your breath away.

Continue reading 911 2.2S Engine Rebuild – Part 10: Almost Complete

911 2.2S Engine Rebuild – Part 7: Gentlemen Start (Rebuilding) Your Engines

Magnesium crank case + new 3.2 Carrera oil pump
Magnesium crank case + new 3.2 Carrera oil pump

Fri 4th Oct 2013

I dragged my friend and neighbour Stan along to Jaz Porsche at Wembley see what I hoped would be a reasonably complete, built-up bottom end .

Continue reading 911 2.2S Engine Rebuild – Part 7: Gentlemen Start (Rebuilding) Your Engines