Doug_B_928

Hi All,

In preparing for my first TB&WP job, I could not find a detailed procedural write-up for a 16V engine with pics. So, here it is. Rather than splitting it up into multiple posts, Rennlist has graciously agreed to host it on their server. The link at the end of this post will begin an automatic download of the pdf from the Rennlist server. I really appreciate the help that I have received from the 928 community so far, and I hope that others will find this to be a useful resource.

So that you know what is covered before downloading, here is the introduction and table of contents from the document:

"This is a procedural write-up I created following my first DIY timing belt change. There wasn’t a newbie rated procedural guide with pics for a 16V so I thought I’d put this together so I could use it when I do the job again and in case others would find it helpful. I am not a mechanic nor am I a 928 expert. One takes this job on at their own risk, but Roger Tyson (928sRus), Wally Plumely (928 Specialists), Jim Morehouse, and Dwayne encouraged me to do the job myself and I’m very thankful as I found it to be a lot of fun. I used Dwayne’s (Dwayne’s Garage: http://dwaynesgarage.norcal928.org/) pictorial write-up for his 32V 87 as my base, added in information from various other sources on the web (Pirtle, Bill Ball, Sharkskin, the FWSM, etc.), and then figured out the differences between my 16V and Dwayne’s 32V as I completed the procedure. Huge thanks to Dwayne for his efforts in his write-up. I would not have undertaken the job without it. This write-up is essentially a 16V supplement to his, with additional information that I picked-up along the way. I have organized it exactly the same as Dwayne’s and tried to keep everything (the text and pictures) as similar as possible so that interested readers can compare the differences between doing the jobs on the two different motors. The 16V job is simpler in several ways, and I’m hoping that other newbies will find this helpful because they won’t have to go through the trouble of figuring out the differences between the 16V and 32V along the way. Having said that, Porsche was always making changes, and previous owners/mechanics may have made modifications, and so others’ experiences with 16Vs may vary."

Table of Contents
Chapter 1: Parts, Tools and Preparation
Chapter 2: Drain Coolant and Remove Coolant Hoses
Chapter 3: Removing Accessory Belts
A. Power Steering Pump
B. Air Pump/Fan
C. Alternator
D. Air Conditioner Compressor
Chapter 4: Removing the Fan Shrouds and Fan
Chapter 5: Loosening Power Steering Pump Bracket, Removing Alternator, Removing Oil Dipstick Tube, and Removing Oil Return Hose and Tube
Chapter 6: Removing the Upper Cam Gear Covers and Setting the Crank to 0TDC
Chapter 7: Removing the Accessory Belt Pulley Assembly, Centre Timing Belt Cover, and Harmonic Balancer.
Chapter 8: Removing the Tensioner Roller Assembly and Timing Belt
Chapter 9: Removing the Water Pump
Chapter 10: Removing Oil Pump Gear and Rear Timing Belt Cover
Chapter 11: Removing the Oil Pump, Replacing the O-Ring and Oil Pump Seal
Chapter 12: Installing the Rear Timing Belt Cover, Crank Gear, and Oil Pump Gear
Chapter 13: Repairing and Replacing Tensioner Rollers and Tensioner Bushings
Chapter 14: Removing and Repairing the Timing Belt Tensioner
Chapter 15: Installing the Water Pump
Chapter 16: Installing the Timing Belt Tensioner
Chapter 17: Changing the Cam Gear Seals
Chapter 18: Installing the Timing Belt Tensioner Roller Assembly
Chapter 19: Installing the Timing Belt and Setting Tension
Chapter 20: Installing the Centre Timing Belt Cover
Chapter 21: Install Upper Cam Gear Covers and Reconnect A/C Compressor Wire
Chapter 22: Installing the Power Steering Pump Bracket, Alternator, Oil Dipstick Tube, Oil Return Tube and Hose, and Fan Assembly
Chapter 23: Installing Accessory Belts and Pulleys
A. Tensioning the Air Conditioner Compressor Belt
B. Tensioning the Alternator Belt
C. Tensioning the Air Pump/Fan Belt
D. Tensioning the Power Steering Pump Belt
Chapter 24: Installing Coolant Hoses
Chapter 25: Installing Lower Fan Shroud, Upper Fan Shroud, and Intake Tubes
Chapter 26: Wrap Up


Here is the link to the download: http://static.ibsrv.net/autocomm/Con...ber%202011.pdf

chrly924s

Wish I had of had thiis three weeks ago when I did my 81. Thanks, this will come in handy when it comes time to do my 83.

genikz

WOW. Nice work! I'll keep this handy when the time comes for my service.

EC928NC

Thanks. Already did an 85 years ago. Looking forward to using this guide when I do my 79's this winter.

Doug_B_928

Thanks, guys! It's great to know that you find it useful.

Bill Ball

WOW! Doug, are you sure you aren't Dwayne's brother?

Andre Hedrick

My thoughts too!

John Speake

Excellent write up - many thanks !

I have one question - on page 53 you say it is possible to remove the centre cam cover with removing the accessory belt pulley ? So why remove it ?

z driver 88t

Wow! That is a great write-up. My thoughts exactly re: Dwayne's brother. Must at least be a long lost cousin. Thanks a ton for putting so much effort into this. My '84 isn't due for a while, but I was dreading tackling that job for the first time.

Doug_B_928

I'm his grateful pupil. Dwayne

Doug_B_928

Thanks, John.

If you just want to have a look behind there you don't need to go to the trouble to remove the crank bolt and pulley assembly. Of course, if you want to change the belt etc. it has to come off.

Also, there is probably an easier way, but in my case the tolerance for putting on the air pump/fan belt required me to have the crank bolt loose such that the pulley stack would spin. That allowed me to turn the belt to get it on the air pump pulley. Does make me wonder about how one would do a roadside broken fan belt replacement.....

Doug_B_928

No need to dread it; it's a really fun job.

checkmate1996

WOW!!! Very nicely done! I know that took a long time to write up and take the pictures. Thank you for your contribution to the community!

Doug_B_928

You're most welcome!

Mike LaBranche

Outstanding write up. Thanks very much on behalf of all 16v tb/wp wrenches that will follow. Very pleased to see the t-belt dance lives on; I grew up on Pirtle and it remains my favorite step. Way to go.