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Complete engine rehabilitation 3.2 G series coupe 1985

Complete engine rehabilitation 3.2 G series coupe 1985

Date
Words
Jordi Edo

Engine repair 3.2

3.2 G-series engine rebuild, 1

engine block already closed

Complete process of engine rebuild of a 3.2 G series.

Main reasons?

Mainly due to non-optimal engine compression testing and oil leaks from engine block.

Tests?

We perform engine compression tests.

Oil leaks

The most likely are the timing and lower part rocker covers, although the upper part is made together.

If the oil leaks are from the block, it forces us to carry out a complete engine repair.

The 3.2 G-series engine as it arrived at the workshop, on the stand
The 3.2 G-series from the intake side before teardown
The 3.2 G-series flywheel and clutch, still fitted
The 3.2 G-series seen from the air filter side, bodywork behind
The 3.2 G-series silencer and exhaust pipes, before removal
The 3.2 G-series with the air filter and intake complete
Front view of the 3.2 G-series with the cooling fan and exhaust
The 3.2 G-series with the intake removed, at the start of the teardown
The 3.2 G-series slung from the strap to come off the stand
The 3.2 G-series flywheel exposed, the tinware coated in oil
Detail of the 3.2 G-series flywheel ring gear
The 3.2 G-series flywheel and cooling tinware before cleaning
The 3.2 G-series flywheel, sump and tinware still in place
The 3.2 G-series engine lowered onto the workshop floor on the jack
Detail of the 3.2 G-series airbox and ducting
The 3.2 G-series on its cradle, fan and intake visible
Front view of the 3.2 G-series with the gold fan and alternator
Detail of the 3.2 G-series throttle body and intake manifold
Rocker cover and wiring of the 3.2 G-series before teardown
Exhaust manifolds and pipework of the 3.2 G-series, dirty from use
Oil lines and sensor of the 3.2 G-series, grimy after years of service
Detail of the 3.2 G-series distributor before removal
Intake manifold and throttle body of the 3.2 G-series, still fitted
Porsche rocker cover and spark plugs of the 3.2 G-series
A part of the 3.2 G-series intake system, removed onto the bench
The 3.2 G-series with part of the intake already removed
Cylinder head and cooling fins of the 3.2 G-series, with oil residue
Fuel pump and linkage of the 3.2 G-series before removal
The 3.2 G-series with the throttle body off and the ports open
Intake manifold of the 3.2 G-series seen from above, before removal
Pump, lines and cooling fins of the 3.2 G-series, with built-up grime
The 3.2 G-series with the intake runners and rocker cover exposed
The 3.2 G-series with the cooling fan exposed, in the workshop
Front view of the stripped 3.2 G-series, with the fan and alternator
Detail of the 3.2 G-series engine mount and pipework
The 3.2 G-series sump caked in oil residue, before cleaning
Detail of the 3.2 G-series sump and oil filter
The 3.2 G-series with the exhaust manifold and sump exposed
The 3.2 G-series heads with the covers off and the ports open
Top view of the 3.2 G-series heads with the rockers exposed
The 3.2 G-series cylinder head with the intake ports open
Detail of the 3.2 G-series cooling fan and its housing
The 3.2 G-series with the heads open and the fan still fitted
The 3.2 G-series heads stripped on the engine, before removal
The 3.2 G-series with the heads off, fan housing still in place
Plug leads and head fins of the 3.2 G-series, before removal
Detail of the ignition wiring over the 3.2 G-series head
The 3.2 G-series cooling fan removed, with the alternator inside
The 3.2 G-series rocker cover removed, with the gasket and oil residue
The 3.2 G-series stripped in the workshop, sump and pulley visible
Side of the stripped 3.2 G-series, with the crankshaft pulley
The 3.2 G-series with the fan off, cooling fins exposed
The 3.2 G-series block with the oil lines and filter still fitted
The 3.2 G-series with the heads removed and the rockers exposed
The 3.2 G-series block upright on its stand, after teardown
The 3.2 G-series block stripped and ready for cleaning
Detail of the 3.2 G-series crankshaft pulley after teardown
The 3.2 G-series block upright, head studs exposed
The 3.2 G-series timing chain housing opened, with the chain and tensioner
Detail of the 3.2 G-series timing sprocket and chain
Rockers and rocker shaft of the 3.2 G-series, wear visible
The 3.2 G-series head with the valve springs fitted, on the block
Another view of the 3.2 G-series head with the springs and the chain below
One 3.2 G-series piston still in its bore, beside the removed heads
The 3.2 G-series cylinders on the block, with their cooling fins
Detail of a 3.2 G-series cylinder on the crankcase, before removal
Worn timing chain guides and rails from the 3.2 G-series
The 3.2 G-series block with one cylinder and the chain exposed
A 3.2 G-series piston coming out of its bore during teardown
The 3.2 G-series crankcase with the cylinder spigots exposed
Removing a head stud from the 3.2 G-series crankcase
The 3.2 G-series timing chain over the crankcase, cylinders removed
The 3.2 G-series rockers on their shaft, in the crankcase
The closed 3.2 G-series crankcase on its stand, after full teardown
The 3.2 G-series crankcase from the side, with the fan housing
Sprocket, tensioner and timing chain of the 3.2 G-series, removed
Detail of a 3.2 G-series rocker with the oil and wear visible
Rockers and valve guides of the 3.2 G-series before cleaning
The 3.2 G-series rockers in a row on the crankcase
Detail of the 3.2 G-series rocker gear and valve springs
Detail of the 3.2 G-series rocker and valve spring, with the old oil
The 3.2 G-series crankcase opened with the timing chain exposed
The 3.2 G-series crankcase with the cylinder seats sooted up
The 3.2 G-series case with the guides and cylinder seats exposed
One 3.2 G-series cylinder still in place on the crankcase
The 3.2 G-series chain guides removed, with the measurements noted
The 3.2 G-series crankcase on the stand, with the flywheel and studs
Heating a 3.2 G-series case stud with a torch to extract it
Marking cylinder number 2 of the 3.2 G-series during teardown
The 3.2 G-series crankcase with the chain housing open and the tooling
The 3.2 G-series crankcase on the stand with all the seats exposed
Extracting a stud from the 3.2 G-series crankcase with the puller
The 3.2 G-series crankcase with the cylinder seats and crankshaft exposed
The 3.2 G-series crankcase split in two halves, with the crankshaft and rods
Crankshaft, rods and intermediate shaft of the 3.2 G-series in the opened case
Cleaned 3.2 G-series head, with the valves and the blue sealing ring
Detail of a 3.2 G-series crankshaft journal and the timing gear
Journals and counterweights of the 3.2 G-series crankshaft, removed
The 3.2 G-series oil pump removed, with its mesh pickup
Pulling the 3.2 G-series intermediate shaft gears in the bench vice
3.2 G-series cylinders masked off to protect the machined surfaces
The 3.2 G-series crankcase cleaned and closed, with the chain in place
The 3.2 G-series crankcase upright with the new cylinders fitted
The 3.2 G-series block being assembled, cylinders and chain in place
The cleaned 3.2 G-series crankcase on the stand, new studs fitted
The 3.2 G-series block under assembly, timing chain hanging
The 3.2 G-series on the stand with the head studs fitted
The 3.2 G-series block in the workshop during the assembly stage
Checking the 3.2 G-series block with a dial gauge
Setting the 3.2 G-series valve timing with the dial gauge
The 3.2 G-series with the cylinders and heads fitted, on the stand
The 3.2 G-series pistons in their bores, ready for the heads to go on
The 3.2 G-series block with the new cylinders and the chain fitted
The 3.2 G-series with the heads on and the tappets visible
The 3.2 G-series half assembled, seen from the timing side
The 3.2 G-series with the heads and valve springs now fitted
3.2 G-series engine rebuild, 118
3.2 G-series engine rebuild, 119
3.2 G-series engine rebuild, 120
3.2 G-series engine rebuild, 121
3.2 G-series engine rebuild, 122
3.2 G-series engine rebuild, 123
3.2 G-series engine rebuild, 124
3.2 G-series engine rebuild, 125
3.2 G-series engine rebuild, 126
3.2 G-series engine rebuild, 127
3.2 G-series engine rebuild, 128
3.2 G-series engine rebuild, 129
3.2 G-series engine rebuild, 130
3.2 G-series engine rebuild, 131
3.2 G-series engine rebuild, 132
3.2 G-series engine rebuild, 133
3.2 G-series engine rebuild, 134
3.2 G-series engine rebuild, 135
3.2 G-series engine rebuild, 136
3.2 G-series engine rebuild, 137
3.2 G-series engine rebuild, 138
3.2 G-series engine rebuild, 139
3.2 G-series engine rebuild, 140
3.2 G-series engine rebuild, 141
3.2 G-series engine rebuild, 142
3.2 G-series engine rebuild, 143
3.2 G-series engine rebuild, 144
3.2 G-series engine rebuild, 145
3.2 G-series engine rebuild, 146
3.2 G-series engine rebuild, 147
3.2 G-series engine rebuild, 148
3.2 G-series engine rebuild, 149
3.2 G-series engine rebuild, 150
3.2 G-series engine rebuild, 151
3.2 G-series engine rebuild, 152
3.2 G-series engine rebuild, 153
3.2 G-series engine rebuild, 154
3.2 G-series engine rebuild, 155
3.2 G-series engine rebuild, 156
3.2 G-series engine rebuild, 157
3.2 G-series engine rebuild, 158
3.2 G-series engine rebuild, 159
3.2 G-series engine rebuild, 160
3.2 G-series engine rebuild, 161
3.2 G-series engine rebuild, 162
3.2 G-series engine rebuild, 163
3.2 G-series engine rebuild, 164
3.2 G-series engine rebuild, 165
3.2 G-series engine rebuild, 166
3.2 G-series engine rebuild, 167
3.2 G-series engine rebuild, 168
3.2 G-series engine rebuild, 169
3.2 G-series engine rebuild, 170
3.2 G-series engine rebuild, 171
3.2 G-series engine rebuild, 172
3.2 G-series engine rebuild, 173
3.2 G-series engine rebuild, 174
3.2 G-series engine rebuild, 175
3.2 G-series engine rebuild, 176
3.2 G-series engine rebuild, 177
3.2 G-series engine rebuild, 178
3.2 G-series engine rebuild, 179
3.2 G-series engine rebuild, 180
3.2 G-series engine rebuild, 181
3.2 G-series engine rebuild, 182
3.2 G-series engine rebuild, 183
3.2 G-series engine rebuild, 184
3.2 G-series engine rebuild, 185
3.2 G-series engine rebuild, 186
3.2 G-series engine rebuild, 187
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