axl911

I got my rebuild kit from Pelican Parts. The heads were done by Ollie's.

KirkF

Does Pelican have one kit with all the gaskets,rings, etc? Or do you have to dig around and order it all seperately?
I didn't see a kit on their site.

kirk

axl911

They actually have 2 kits. One for the top end and one for the bottom end. I ordered both. The bottom end is cheap, but comes with couple of seals that if you buy separately, will cost as much as the bottom end kit itself. Actually, Pelican has a rebuld wizzard which shows you all the stuff you need for a rebuild. I used that.

axl911

BTW, I documented my rebuild. You probably find it useful.

http://forums.pelicanparts.com/showt...hlight=top+end

KirkF

axl911,

I have been regularly referring to your rebuild text on pelican, its a great resource.
I have looked all over pelican but I don't see a rebuild wizard or top/bottom rebuild kits for the 964?

Am I blind or what?

kirk
(Still waiting for my cam tool by the way, so no progress for me. I am not lucky enough to live near other 964 owners! I understand sundog is going to be continuing his dissassembly this weekend with some handy borrowed tools and advice. So this thread should be picking up again right away)

MARC A. 964 C4

KirkF.
Absolutely fantastic multiplied by 964 equals you! Thanks for the, “Porsche 964 engine reality show”, you taught me many things, and thanks for the photographs, they tell me so much more then endless lines of written words! I only wish I could hear that first turned ignition key, contact, and engine start, record it, and sell it, no better yet, a copy for everyone at Rennlist for Xmas, or Easter!! Thanks,..Marc A.
PS Watched the Grey Cup on Sat. TV Sunday, a good showing for Canada!!

axl911

It's in the Early 911 cars section under the Engine section.

http://www.pelicanparts.com/catalog/..._pg1.htm#item0

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anthony

axl911

Here's the link to the wizzard itself.

http://www.pelicanparts.com/cgi-bin/...engine_rebuild

I think these are the parts.

Engine Crankcase Gasket Set, 911 Carrera 2/4 (1989-98), 911 Turbo (1989-98)
Brand: Victor Reinz [Photo]
930-100-901-04-M17 $51.25
Cylinder Head Gasket Sets

Cylinder Head Gasket Set, 911 Carrera 2/4 (1989-94)
Brand: Victor Reinz [Photo]
964-100-902-00-M17 $272.75

Just email the PelicanParts guys. They would definitely know.

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anthony

JasonAndreas

Kirk,
If you own PET click on the icon that looks like a license plate and it will bring up the repair kits and their contents. Personally I would stick with OE (not OEM or 3rd party) seals & gaskets, I've had bad luck with aftermarket rubber for the 964 and the OE seals cost the same if not a little less.

sundog

Ok, major progress over the holiday weekend and today. I got the harmonic pulley removal tool, (fancy bolt), Cam shaft tool, and cylinder holders yesterday. The engine is now down to the case. Nothing major found in the removal of the timing chains, cam/head assembly, or cylinder/pistons. Followed Waynes Porsche 911 engine rebuild book, and axl's top end post from Pelican. Great resources. Only a couple of things left to the imagination .

Attached are some pictures of the process. I have plenty more if anybody want's them. I guess that I should just start a web site with the whole 9 yards.

The rod on number 3 cylinder is harder to move than the others. It does not rotate freely like the other 5. It also has some side play. I bet that it the bad bearing. Hopefully will split the case later this week to confirm.

bhensarl

Wow! Great pics. You should definitely make a web site. I, for one, would definitely come visit it.
Brian

Marc Shaw

Great progress so far and thanks for the pictures.

Do you have any further info or pictures on the timing chain cover removal as those gaskets need replacing in my car but I'm not sure how to get the covers off.

I am assuming: drain oil, remove exhaust, remove covers, replace gaskets, replace covers.

Anything else I should know?

Thanks! Marc

sundog

Removal of the timing chain covers may require the removal of a lot of parts. They are hidden behind the muffler, the support for the air conditioner support, the muffler heat shield, and the engine support. You can probably get access without removing all of these. In my case a couple of the bolts were "loose", and you may try to retorque them to the appropriate values and see if that stops the leak.

Crivens

Well Done on taking the plunge.
The only problem with taking the plunge is once youve done it once, you keep on doing it. You get to the point where you dont want to take your car to any expert after that, and experts are goood to have/use.

Sometimes the amount of info (Here-say) on the internet can be a good thing, others a real pain in the ****, I would hope you have a real expert to call on if things get tough.

Bearings in your oil doesnt sound good.
The 964s dont tend to suffer on the bottom end, mine did 190k miles and was still perfect at the bottom end. (changed them anyway).

Ive just finished my second 964 rebuild but I had the benefit of working at Porsche specialists (me non techy) and access to the tools and expertise.

I have to say though that in terms of rebuilding your engine.

1. Getting it out - anyone can do it to varying degrees of success, it will ultimately come out. thank god for lifts!

2. Strip down, I did mine on the garage floor in the middle of winter, just be organised and keep everything. Got to keep your eyes open when examining parts for wear.

3 - Cleaning, the biggest part of the rebuild job, can do it anywhere with lots of chemicals.

4 - Machining, Go to town on the bottom end, line bore etc, 99% of time not needed unless something really bad has happened, but then again - i wouldnt re-use a suspect crank regardless of grinding and polishing.

5- Heads, Put em in a box, send them to qualifies machine shop and get them back shiny and new fully built up to correct heights.

6- assembly, bottom end, no problem, just take your time and double check everything. Have some help when putting cases together.

7- Heads up. Easy to install, study the cam sealing and sprocket installations, but dont worry it only really seals one way.

8 - Cam timing, if in doubt, get an expert to do it.

9 - Dressing, like stripping, cant go wrong, just clean and polish it as you go, wiring is easy.

Add to this little mix a lot of time cleaning with chemicals and you have your first rebuild.

Confident in my engine rebuild I opted to rip out my 3.2 and pop my 964 engine in. Rust is another demon ive not tackled yet. - dont laugh at the bodywork!.

My 964 engine in its new home

Crivens

7hrs, I dont doubt it though 3hrs to disconnect the electrics?

Makes me chuckle.
With a set of ramps (and a boss who kept popping into the workshop to make sure I wasnt using his resources on his time).

I whipped my 3.2 engine out in 15-20mins.
Zip off the driveshaft, disconnect the fuel line, disconnect the electrics (like 5 mins). off with the breathers, away with the gbmounts, up with the jack, down with the engine mounts and hoist he car up in the air at the press of a button.

Putting the 964 engine in can be done in the same time connecting it up is easier than the 3.2. Its all the bloody undertrays and plastic bits that take the time.

filling it with oil is another matter.. that takes the time on the 964 (drink you bugger, drink!).