Doug Donsbach

Agreed that it makes sense to replace those but there is no way you'll get oil / cooler intermix if they fail. Because they're external to the engine, worst case is you'll end up with an oil or coolant (or both) leak. But intermix - no way.

15psi

update: spent more time cleaning up and organizing tools, but eventually got back to engine. I removed the mufflers, brackets to gain access to valve covers. They were very dirty so I cleaned then and vacuumed the engine. I'll fab the cam locating tool tomorrow and pull the valve cover off.

Replaced the water pump. After reading about the nightmares people have with the bolts, I decided to just remove the cats and the engine mount bracket. Takes 10 minutes to remove and turns removing the water pump into a 5 min job. Also get a hose loosening tool for the hoses. After 10 years they are glued to the pipes. Really makes a difference.

Removing the engine makes all these difficult projects very easy.

15psi

Thanks for your help on Friday. Karl (Doc) eventually got it out. Dropping the engine did help. Makes a difference once you can visualize it.

Did you get the 2 post lift setup?

ltusler

The only other engine thats easier than a 996 to remove is a 356. Since I sold my 356 to get my 996, I now refer to it as the "6". I did have the RMS failure, but no IMS, my ultimate was a crank failure. But thats ok, it lead me to an opportunity for a upgrade. Now were packing a Jake Raby Flat 6 Innovations 3.8 with all the goodies and looking forward to many years of fun! PS if anyone in MN wants to do a pull and retrofit, my lift is available.

jasper

I'm liking this forum more every day.

No more fart jokes or comments about buying parts that don't fit.

Barn996

What a great write up 15psi, and pulling the engine/trans out makes so much sense especially if you have a luandry list of components to replace. How long did it take just to remove the engine/trans? Thanks for all the pics and info...well done.

15psi

Thanks!

I'm thinking about 5 hours (with power tools). Way too much time was wasted on the AC compressor- I know better now. Probably shave 25-30% off that time if I were to do it again.
When I'm done I'll post all the part numbers, 'must have' tools and best time savers.

15psi

I had a 356 also- definitely the easiest to remove. I saw a TV program where 5~6 guys removed a VW engine in something like 7 minutes to break a World record. Pretty amazing.

4Scargo

I'm am no mechanic. But, I removed the engine out of my '76 912E in, what, half hour....20 minutes of that was taking off the tin! And, did I say that I am not a mechanic.

Thanks PSI, great stuff.

ITusler...where you at?

2K7TTMIA

awesome write up and pics! +1 on DIY'ers owning these cars and sharing basic, and not so basic mechanical work.

ltusler

I'm out in Maple Grove. Co Rd 47 and Vicksburg. I usually charge a case of good German beer for lift access.

15psi

Continuing to make good progress...

In the last 2 evenings, I decided that mounting the engine to a engine stand would make the cam work much easier and I wouldn't have to worry about the lifters falling out or wishing I had 4 hands. This meant cutting the stand so I could use the OEM bolts. Another hour consumed.

I welded up the 'cam locator tool' that holds the cams in place while you take the valve cover off. Also made the threaded tool that compresses the Variocam. (thanks Dharn55 for the info!)

Now with the engine on a stand and the proper tools I tackled the removal of the cam cover and replacing the VarioCam pads and chains. Everything went well. The top pad was VERY worn, glad I did this.

The real surprise was the loose spark plug. It was literally taken out with just my finger tips. This explains the chirping noise that started recently, that I couldn't find. Also the spark plug electrodes were worn. I'd assume that they were originals.

Tonight I finish assembling the cylinders 1-3 and move to 4-6. With any luck, I will also mount the transmission back and start to move engine back into the car.

ivangene

nice work Jim!!

Barn996

Indeed, and great pics of work entailed.

15psi

Friday Update:
I accomplished a lot last night- but no pics - sorry-
The good news is that the 4-6 VarioCam pads/chains are done. I had about 3 hours invested in 4-6 bank. Then turned the engine on the stand and started on the 1-3 bank. It took me ~45 mins. Bam!
[I really don't see doing this while the engine is in the car, and ideally you will need a motorcyle jack (remove engine from car), engine stand (work on and rotate engine), and cherry picker (place engine on engine stand) to work on engine outside the car]

It was interesting that none of the plugs were tight and the one was already coming out. I put in new sparkplugs, spark plug tubes and seals which only took 5 mins. I know I keep saying it, but this engine is so easy to work on when it is outside of the car.

What's next for the weekend? Weld a nut on the broken header bolt and remove. I done this many many times and only had to drill once. Then put the mufflers on. Install clutch, etc and then mount transmission. Roll it under the car, jack it up and start reconnecting eveything. Fill with water and oil. Replace tires and bumper.

Will some luck I'll be driving Sat or Sun.