Per Wayne Dempsey...
Time to Rebuild?How to Rebuild and Modify Porsche EnginesTime-sert official site The 1974-77 magnesium cases are most known for their pulled head studs. How does this happen? Magnesium is softer and lighter than aluminum. On the very early magnesium cases (1973 and earlier), the engine didn’t stress the limits of the magnesium case too much. With the advent of newer, and tougher emissions restrictions in the late 1970s, hotter running engines (hotter engines give off less emissions) began to stress the limits of the magnesium case. In addition, the increase of the displacement of the engine placed additional stresses on the engine cases. Particularly if the engine becomes overheated, it will expand and place additional stress on the threads of the studs that are inserted into the case. These stresses were exacerbated by the fact that the cylinder spigot was enlarged to accommodate the larger 2.7L cylinder. The enlarged bore removed crucial material in the area near where the cylinder head studs are mounted. The result is that the metal threads in the magnesium case yield, and begin to pull out. Once the engine cools down to it’s normal operating state, the stress subsides, but the studs remain pulled out of the magnesium case. The result is that the barrel nuts on the end of the studs become loose and fall off. Subsequent attempts to re-torque the nuts almost always results in further pulling of the stud. The appropriate torque for the heads can longer be maintained, and as a result, the heads become loose. This often creates a distinctive exhaust leak at the interface between the head and the cylinder. This phat-phat-phat sound is typical of a 2.7L engine with pulled head studs.
How can you tell if you have a pulled head stud? Simply pull off the valve covers (upper and lower), and check to see if you have any head stud barrel nuts floating around the inside the spark plug area. If you do, then chances are good that your magnesium case has pulled at least one stud. If the barrel nuts are still attached to the head studs, take a 10mm allen-head tool, and attempt to tighten them to factory specs (see Appendix X for the specification for your year engine). If the nuts simply spin and spin, then you probably have a pulled head stud. Don’t keep tightening it, as you can pull the stud so far out of the hole that it will be difficult to remove the nut later on when you disassemble the engine.
The repair involves a complete teardown of the engine, as you cannot easily and effectively repair the case without the use of a precision milling machine or drill press. The fix for pulled head studs is the installation of what are known as case-savers. These are threaded steel inserts that are installed into the case and reinforce the threads to be stronger than the bare metal threads within the case. The case-saver has a larger diameter than the original head stud, which results in more material contact area to grip the
time-sert. In addition, the case-saver is a larger, coarser thread, which means that there is more material between each thread. More material translates into greater strength along the axis of the head stud. In simple terms, the case-saver creates a new hole for the head stud that is stronger and tougher than the original one in the case. Case-savers can still pull out of the case, however, this is usually only seen in high-stress, high-compression race motors, or if the engine has been overheated. Placing the case-savers in the magnesium case should make it more than strong enough for street and most race track use.