I didn't know much about 911 engines when I got my 92 C2. It started innocently with an oil change. Then, I did valve adjustment and change out my suspension and brake. Then my car started smoking at idle. After doing everything that I can to fix it, the next thing I knew is that I got the engine out and ready to tear into it.
I won't document the top end rebuild process. Wayne's book does and excellent job of this. But it's not specific to a 964. I am going to use this thread to point out the differences between the Carrera and the 964 during my top end rebuild. Hopefully, this can help someone. So let's get started...
I am using Wayne's book, the factory manual on CD, PET, and this forum to get me through this rebuild.
I won't go into dropping the engine since it's been discussed a million times and the process is the same.
When removing the intake manifold/injection system on top of the engine, it's easier to remove it in 2 pieces. Undo the 6 hose clam on the intake manifold and lift the whole intake manifold assembly up. See pic below.
Lift the intake manifold assembly off and you will have.
Next, remove the injector, fuel lines, wiring harness, etc. assembly as a whole. You may have to remove some other pieces out first. You will be left with nothing except the engine shroud on top.
On the 964, you have to remove the fan belt pulley in order to remove the AC bracket/mount. Undo the 22mm bolt, and the pulley will still be stuck to the crank. There is a special tool to pull the pulley off, but I used a 3 claws 6-inch pulley remover to take it off. Put the claw on the thickest edge of the pulley, otherwise, the pulley edge will bend. The pulley will pop off so be careful. It will land on your toes. The pulley is an integrated pulley and harmonic balancer so it is fairly fragile. Don't bend, drop, or bang on it.
With the AC bracket/mount removed, you can remove the timing chain housing cover.
Note that the 964 uses triple square head bolt nuts. The flywheel bolt is also a triple square design. So pick up a set of these 12 points tools. They are availble in a set of 4 for about $12 at Autozone.
