964 Engine Removal

[allen8590]

So I have removed many engines from early 911's but now I am going to try to remove my '90 964 engine. I am not going to beat the topic to death, but any tips or tricks to share? Also, what are the best books, manuals, or tech articles to help guide me through this process? Thanks in advance

[john walker's workshop]

pretty straight forward. remove all the stuff that's attached to the engine and trans and swing it out of the way. the clutch slave is unbolted and moved to the side. don't forget the oil line at the filter console in the RR fender. that's kind of a pain to get the nut loose. muffler off. cut a paper cup short and collect the steering fluid from the reservoir and pump. have a pan nearby to do several dumps. lower slowly and check for things hanging up. C2 or C4? C4s require some extra removals.

[allen8590]

C4, I am sitting at the shop right now, pulled the deck lid, wheels, and drained the oil from both plugs so far. I took lots of pictures...better safe than sorry. I already see lots of things I am going to have to replace just cause they do not look Porsche worthy. I am pulling the engine as I floated the valve train. Normal driving..I baby the car, but was trying to handle a business call while drive at 70mph. I tested compression on 1 bank, and nada. I pretty much know what to expect when I pull a head and am currently trying to look at upgrades while I have it appart. Any additional input greatly appreciated.

[john walker's workshop]

C4, the hydraulic servos on the right side and nose of the trans are removed with their metal line connected. the nose servo needs some wiggling to come out. the right side one comes out easily, but unbolt the black metal bracket next to it which holds the lines also and move them away together. the console insert comes out inside the car along with a coulple of plugs under it to access the top two bolts to the torque tube. small hands are good. remove the joining clamp allen bolts and slide the clamp forward off the trans splines. remove the lower torque tube bolts only when you are ready to lower the assembly because nothing but 1/8" long alignment sleeves are holding it at that point. keep the eng/trans level with the torque tube so you don't break any expensive stuff. you may want to rent a big transmission jack because the unit is heavy and awkward. the rest of the stuff should be obvious.

[allen8590]

John,

I have successfully removed the 2 servo lines as you instructed. I am still trying to figure out the interior console, its mostly apart but I am hung up somewhere. One quick question, Would you suggest removing the rear bumper when doing the drop? Thanks again for all of your help.

[allen8590]

John,

I am trouble removing the console, I am sure I am missing some hidden screws toward the front. I have found this access hole, so I assume the others are forward of this? Thanks

[allen8590]

I guess my main question at this point is this is where I disconnect the torque tube to avoid damage correct? I think after I complete this step I am good to go.

[Tall02]

Dear Fellow Porscher

I pulled my 3.6 engine two years ago and rebuilt the engine on my own. I researched through books, the web and fellow club members when ever I had a question. I hope I can do the same for by supplying a few pointers.

First - research and use all your resources: porsche engine rebuild books and use the web. Many of the Porsche chat forms have good advice.

Second - use plastic sandwich bags to tag and bag everything you take apart. Use a hanging file and deposit the order of parts in the files from front to back. Once you begin reassembling the engine work out of the file from back to front. The Porsche engine has 3 or 4 times the number of component compared to many other engines.

Third - but is the most important - SAFETY - double block under the vehicle for you will be lifting or tilting the rear of the vehicle high. Use a motorcycle lift or transmission lift to support the engine when dropping it.


Fourth - I am attaching a quick progression check list to dissconnect the engine from the vehicle and you can use this project list in reverse when reinstalling it. Many fellow mechanics and Porsche enthusiests helped me and I wish to pass on this advise.

Porsche C2 964 Engine Removal Process


 Disconnect battery
 Remove fuel pump relay
 Raise rear of car on jacks
 Disconnect Blower tube
 Disconnect Blower motor
 Disconnect Distributor plug and belt tension plug
 Disconnect 7 connects on left front side of engine
o O2 sensor, fuel return line, cruise control, white/green/black plugs
 Disconnect oxygen sensor
 Disconnect 3 plugs in fuse box – left side of engine
 Disconnect both ignition coil wires to distributors
 Disconnect A/C compressor and tie to side of car
 Disconnect fuel line on right side of engine
 Drain and disconnect power steering lines
 Disconnect throttle cable from pedal
 Empty oil from engine sump
 Empty oil from oil tank
 Disconnect 2 hard oil lines
 Disconnect and remove rubber oil lines
 Disconnect drive shafts
 Disconnect heater hoses from heat exchangers
 Disconnect starter electrical connection
 Disconnect the ground strap to trans
 Disconnect reverse backup switch on trans
 Disconnect speed cable/sender wire on trans
 Disconnect and remove shift coupler (put in 3rd gear first- which will allow shifting into 2nd after disconnect for clearance to drop trans).
 Remove sway bar
 Pull out throttle cable from tunnel
 Disconnect clutch slave cylinder
 Disconnect accelerator linkage bar
 Disconnect cruise control cable
 Position jack under engine/trans center near exhaust crossover pipe
 Remove trans cross-member (six 17 mm bolts)
 Remove engine motor mount nuts (19mm nuts)
 Lower engine 2 inches (2nd jack may be required since the trans is nose heavy)

 Disconnect Air Flow Meter plug
 Disconnect 2 oil breather hoses from air intake boot
 Disconnect 1 vacuum line –right of air cleaner assy

 The rear bumper may need to be disconnected to give you 2” more clearance. (2-13mm screws per shock and one 10mm screw on back of shock plus a few Phillips screws. Remove right rear taillight to unplug the license light plug.)



Good luck
Keith

[allen8590]

How many bolts on the 964 manual trany/bell housing? I am hung up somewhere right now and I am not sure where.

[Tall02]

Are you dropping the engine with the transmission attached. I recommend the two are left together and seperated once out of the vehicle.

I believe there are two bolts that mount the trans crossmember to the C2 vehicle frame.

[john walker's workshop]

the console does not come out for this job. you work through that small hole to remove the two top torque tube bolts. fun eh?

[Cheyne76]

Easier to remove engine with trans in car with C4's. Did you remove the pin that holds the fork on the release bearing? There are only 4 studs that hold the trans to engine.

[allen8590]

Ok, I have the removed the joining clamp allen bolts trans splines, but I cannot get the joining clam to slide forward? Any suggestions?

[allen8590]

The engine and gearbox drop went excellent! I did not make any additional work for myself by accidentally breaking anything : )....Thanks to all the help. Just in the market for some performance cams, engine tin/sheet metal, and some performance heads.

[911Obbie]

Originally Posted by Tall02

Dear Fellow Porscher

I pulled my 3.6 engine two years ago and rebuilt the engine on my own. I researched through books, the web and fellow club members when ever I had a question. I hope I can do the same for by supplying a few pointers.

First - research and use all your resources: porsche engine rebuild books and use the web. Many of the Porsche chat forms have good advice.

Second - use plastic sandwich bags to tag and bag everything you take apart. Use a hanging file and deposit the order of parts in the files from front to back. Once you begin reassembling the engine work out of the file from back to front. The Porsche engine has 3 or 4 times the number of component compared to many other engines.

Third - but is the most important - SAFETY - double block under the vehicle for you will be lifting or tilting the rear of the vehicle high. Use a motorcycle lift or transmission lift to support the engine when dropping it.


Fourth - I am attaching a quick progression check list to dissconnect the engine from the vehicle and you can use this project list in reverse when reinstalling it. Many fellow mechanics and Porsche enthusiests helped me and I wish to pass on this advise.

Porsche C2 964 Engine Removal Process


 Disconnect battery
 Remove fuel pump relay
 Raise rear of car on jacks
 Disconnect Blower tube
 Disconnect Blower motor
 Disconnect Distributor plug and belt tension plug
 Disconnect 7 connects on left front side of engine
o O2 sensor, fuel return line, cruise control, white/green/black plugs
 Disconnect oxygen sensor
 Disconnect 3 plugs in fuse box – left side of engine
 Disconnect both ignition coil wires to distributors
 Disconnect A/C compressor and tie to side of car
 Disconnect fuel line on right side of engine
 Drain and disconnect power steering lines
 Disconnect throttle cable from pedal
 Empty oil from engine sump
 Empty oil from oil tank
 Disconnect 2 hard oil lines
 Disconnect and remove rubber oil lines
 Disconnect drive shafts
 Disconnect heater hoses from heat exchangers
 Disconnect starter electrical connection
 Disconnect the ground strap to trans
 Disconnect reverse backup switch on trans
 Disconnect speed cable/sender wire on trans
 Disconnect and remove shift coupler (put in 3rd gear first- which will allow shifting into 2nd after disconnect for clearance to drop trans).
 Remove sway bar
 Pull out throttle cable from tunnel
 Disconnect clutch slave cylinder
 Disconnect accelerator linkage bar
 Disconnect cruise control cable
 Position jack under engine/trans center near exhaust crossover pipe
 Remove trans cross-member (six 17 mm bolts)
 Remove engine motor mount nuts (19mm nuts)
 Lower engine 2 inches (2nd jack may be required since the trans is nose heavy)

 Disconnect Air Flow Meter plug
 Disconnect 2 oil breather hoses from air intake boot
 Disconnect 1 vacuum line –right of air cleaner assy

 The rear bumper may need to be disconnected to give you 2” more clearance. (2-13mm screws per shock and one 10mm screw on back of shock plus a few Phillips screws. Remove right rear taillight to unplug the license light plug.)



Good luck
Keith

Hi- new to the forum.
Do a 964 C@ Tip engine and trav drop.
Going by the workshop manual.
Got the step for of removing the blower motor.
The front bolt turns but does not come out. Thoughts?
Second, how did you remove the grommet from the rear attachment point on the blower motor?
Thanks. Trav

[yeongk]

Hi,

Doing engine drop on my 964 C4 (broken head bolts), but have been stuck while trying to remove the shift rod clamping sleeve. As shown in the picture, not able to align the clamping sleeve to remove the allen screws. Tried to rotate the shift rod even using a pry bar, but it wouldn't budge at all. Would greatly appreciate any tips / suggestions on this.

Thanks,
Yeong

[yeongk]

Update -- was able to remove 2 8mm Allen screws. Rotated the front wheel by hand to rotate the drive shaft to align the screws.

[muaxuan2879]

chÃ*o cả nhÃ* - em lÃ* thÃ*nh viên mói ra nháº*p

[Cairo94507]

Hey Tall02 - I like your hanging file tip!