So here we are round 3 of what seems to have been a never ending process. I have to say thanks to a couple of folks before I get into the whole thing. Sean West @ SRM and Stephen Revit for helping me keep my sanity.


I had the car at undercover and got it back with a few things that still needed attention since I am a bit **** with things. It took me several months to complete and get the car in running condition. To be honest it was a task to say the least.


Drove the car around lightly a couple of times before getting ready for the dyno. That brings us to a broken shaft the day before going to the dyno. Engine lost all oil pressure at idle in my driveway. I could not believe that this was happening after all I had gone through already.


So after some careful consideration I decided I would take it apart here at home with the help of a friend of mine.


Attached are a couple of pictures from taking it apart and a couple of the broken shaft. Luck was on my side since no other damage was found internally. We have made a few changes thanks to lots of time on the phone with Sean and Steve good thing neither are attorneys.


Sorry for the long winded post but it has been a long A$$ road.

 

Wow, any ideas on what would shear off the IMS shaft in the oil pump coupling? Is the oil pump sized with some chunk of metal in it?

 

We found nothing anywhere. Oil pump is perfect thank goodness. It was brand new. There was no other damage but the shaft. Crazy as it seems just glad it happened at idle in my driveway.

 

Really strange thing to have happen. I wish I had magnafluxed mine before I put it back in. Glad it didn't tear anything up. If it let go at full speed the computer would shut the car down and it wouldn't be a catastrophic failure anyway I think. What are your plans for reassembly going forward?

 

What are the first two pics, electrical short or fuel line issue?

 

Wow. I've been involved with Porsches for a long time (for the past 20 yrs only hobby-wise. And I certainly don't claim to know everything, but...). The oil pump / intermediate shaft design hasn't changed in longer than I've been alive. I have not heard of any failure like this.

Have you actually disassembled the oil pump or just spun it by hand?

 

Glad to see it coming together jimmy. Its been a difficult road

 

Well as far as the first 2 pics goes. The first is how we found the alternator shorting out against the bolt. The 2nd is the oil feed line to the turbo was pinched and luckily it never actually leaked. That could have been a major disaster.

We disassembled the oil pump and found nothing wrong internally.

It's going back together already engine has been out since October. We did just a couple of minor things differently this time around. Third times a charm right lol.

Doing 12 mm head studs and some other goodies from SRM. If all goes well next week it's going to be back in the car.

Most people we have spoken with have rarely seen that part fail. So who knows what happened.

 

I had the same issue with my alternator. When I pulled my motor, I realized that after wearing through the wire, it had arc'd enough to melt the bracket in your picture in half. I'm assuming this had happened to the previous owner, because I never had any issue with an electrical smell.

It appears there are two different paths/channels on the back of the alternator for the wire. If you pick the wrong one, this is the issue you will get. I know the previous owner had replaced the alternator, so I assume this is when the problem occurred.

Good luck.

Later, Steve

 

I looked a little closer on my computer not the phone. The break in the shaft does not look like a torsional failure. It looks like it had a bending load on it at some point that started a fracture that then propagated. It started at the snap ring groove as would be expected. Magnaflux should have found this. It was probably partially fractured for a long time.

 

what did you change up in the motor besides going to the 12mm studs?

 

It was probably partially fractured for a long time

This ^^^^^^


We assumed the same thing just by looking at how the piece looked.






Mark just a different plenum from SRM adding EGT's from SRM that they have made up so I can have individual readings at each cylinder. It's the details that in the end will make a difference to me. The fact that it did not have any EGT reading and EG pressure is just stupid.


Other than some simple things nothing else was needed. Thankfully no other damage was done.

 

Did you inspect the tip for any fine markings? It could have been dropped. I could imagine the weight of the IMS cracking the hardened metal at that weak point.

 

Yes we looked at it and found no markings on either side.


Here's a few pics from today. It's all cleaned up and coming together nicely. Best part of the deal is it's all local to me.

 

i have seen it in combination with a extrem light flywheel....

the oilpump coupling must have a slight way to move at the new part