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964 C4 light refurb

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Old 03-21-2021, 05:42 AM
  #1516  
John McM
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Engine and box going back in.





Spot the socket used to tighten the top bolt on the starter motor.
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Old 03-21-2021, 05:45 AM
  #1517  
John McM
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Motor and box are back in the car. Now the reconnections start as well as fluid fills.

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Old 03-21-2021, 06:22 AM
  #1518  
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Excellent work and again- thank you for the excellent documentation. Its threads like this that make this forum for me. Still planing to get over there and fill you up with a beer or 2 some day. Until then- Cheers from Japan!

Looking forward to hearing about the results. Surely your left leg will be relieved.

Pete
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Old 03-21-2021, 09:03 AM
  #1519  
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Originally Posted by John McM
When the engine and box are back in the car some items are difficult to access so I made a point of cleaning earth points and straps.
Great, but often over looked detail, going out in the garage to do this on mine now while the lump is out. Thanks for suggesting.
Old 03-21-2021, 04:25 PM
  #1520  
John McM
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Another C4 specific hurdle. I torqued the engine mounts and transmission bolts then went to slide the spline tube back over the gearbox spline and it was a no go. The gearbox spline was slightly lower than the front spline.

A bit of thinking and a check with Spokes confirmed the solution. Untorque everything and use the engine height to control the gearbox spline position (engine down makes the spline pivot up on the transmission carriers).

Sorted with the help of the AC Jack.



Last edited by John McM; 03-21-2021 at 05:42 PM.
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Old 03-21-2021, 04:42 PM
  #1521  
kos11-12
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Well done and thanks for all the details. I must admit it comes spot on as I am preparing to drop my C4 engine
I like your cisor lift, it looks like it makes the work easier, I guess you have to rise a low car to be able to slide it under.
Old 03-22-2021, 03:19 AM
  #1522  
John McM
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Originally Posted by kos11-12
Well done and thanks for all the details. I must admit it comes spot on as I am preparing to drop my C4 engine
I like your cisor lift, it looks like it makes the work easier, I guess you have to rise a low car to be able to slide it under.
My first drop was done with Esco stands and the AC Jack so it is possible. However I far prefer the scissor lift. It needs to have ramps or be recessed in the ground to work on our cars though.
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Old 03-23-2021, 06:09 AM
  #1523  
John McM
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Clutch lines connected (RHD C4 version). Actuator inserted. Everything torqued.





Old 03-24-2021, 07:12 AM
  #1524  
John McM
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Not my best day on the tools.

1. I connected the battery and the Durametric to bleed the actuators. I turned the ignition key to on and a liquid gushed out the back. I hadn’t taken out the DME or reconnected the fuel filter so I was pumping fuel over the garage floor.

2. The Durametric took an age to connect and then only gave me a transverse actuator bleed option which did nothing. I checked the fault log and got an error 32. Work for another day. BTW it did bleed with a motive. Go figure.

3. I connected the fuel filter, PS pump and air con, then filled the oil, which burped out and down the tray on to the secondary exhaust.

4. I bled the clutch and the action using a hand is beautiful. I stopped there for the day.



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Old 03-24-2021, 07:20 AM
  #1525  
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It had to happen sometime! Went like a dream until then, so put it down to experience!!
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Old 03-25-2021, 04:58 AM
  #1526  
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So close now. I took off the secondary muffler and heat shield and thoroughly cleaned the spilt oil and PS fluid off them. Then it was wheels, pedal board etc. I’m waiting on some valve cover washers then I will fit the rear heater fan and air box. Otherwise it’s ready to go. Sitting in the car and pushing the clutch pedal is light years away from the stiff graunching RS clutch. I don’t think it was the RS bit, I suspect it was a failed pressure plate.




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Old 03-26-2021, 04:25 PM
  #1527  
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Valve cover washers were sourced via Rennlist member, Spokes, so I was able to complete the reinstall of the rear heater fan and airbox.

I installed a new filter and was surprised to see it was more than four years since I last did that. Many road trips on back roads had made it a bit dirty.

With that done, I sat in the car, turned the key and heard a screeching noise as it fired. I realised it was the PS pump refilling and the noise went away. I pushed in the clutch, selected reverse and moved back two metres. I then selected first and moved back to the starting point. WOW. It is night and day. The action is so light and progressive it’s like a new car. Why I persisted so long with a rock hard clutch and rough take up point is beyond me.

The next step is to run around the neighbourhood and check for action and leaks.



Old 03-26-2021, 04:48 PM
  #1528  
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Originally Posted by John McM
Not my best day on the tools.

1. I connected the battery and the Durametric to bleed the actuators. I turned the ignition key to on and a liquid gushed out the back. I hadn’t taken out the DME or reconnected the fuel filter so I was pumping fuel over the garage floor.

2. The Durametric took an age to connect and then only gave me a transverse actuator bleed option which did nothing. I checked the fault log and got an error 32. Work for another day. BTW it did bleed with a motive. Go figure.

3. I connected the fuel filter, PS pump and air con, then filled the oil, which burped out and down the tray on to the secondary exhaust.

4. I bled the clutch and the action using a hand is beautiful. I stopped there for the day.
Hi John,

May I ask are you running the oem chip or an aftermarket chip like Steve Wong chip? The reason I inquire is that I have a Steve Wong chip for my LWF/ Clutch/bypasses/ etc. Currently, I am using the ScanTool software and T-OBD plug by Bergville. It too is having the same issues of connecting. I''m wondering if having something other than oem causes the lengthy connection time. I would like to purchase a diagnostic tool that is able to do the ABS/PDAS bleed but worried about not being able to connect.
Old 03-26-2021, 04:55 PM
  #1529  
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John, any chance you have photos of the camshaft journals in the carrier from when you did the rebuild?
Old 03-26-2021, 11:55 PM
  #1530  
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Originally Posted by Deserion
John, any chance you have photos of the camshaft journals in the carrier from when you did the rebuild?
For some reason it wasn’t something I focussed on. This is the best I have.



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