Information gap to rebuild a '93 3.6

[Don Settergren]

I am the proud owner of a ’93 C2 Cabriolet that needs the engine pulled and inspected after being flood damaged. I know the 3.6 is far more complex than rebuilding my old 912 engine (understatement), so I bought the Dempsey 101 and Rebuild bibles. I'm pretty sure I can pull off the rebuil; however, you all are going to see my name on this board quite a bit this winter. Anyway, the books, suggested tool kits, engine dropping methods, and rebuild kits posted on Pelican only cover to 1989 and don’t cover my newer '93 3.6 engine. I scoured the bulletin boards trying to find the definitive information, but without any luck. Maybe I missed a link or didn’t search thoroughly enough – can anyone help me fill this information gap?

[Glenn from Denv]

Hi Don,

I did my 94 3.8l race motor using only the Rebuild book, the 964 workshop manuals and the 964 Without Guesswork book. There were a few differences but they weren't too bad. A semi-educated guess helped in some places but I think that this was due to the fact that it's a race motor without all of the sundry accessories that are on a street motor.

Good luck on your rebuild!

[ChrisBennet]

Glenn,
Did you find the "964 Without Guesswork" helpful? Is it worth $65 if you already have the factory manuals?
-Chris

[Don Settergren]

Thanks for the reply... I have the Bentley Without Guesswork Technical Manual. I also have a copy of Mitchell's OnDemand Repair CD that has proven useful for electrical wiring diagrams - I'll study it tonight for engine building information. Do you think the Factory Service Manuals are a must, or would Bentley's Service Manual be sufficient for the really technical areas that might slow me up?

[JasonAndreas]

The Bentley service manual is fine if all you need to know is the torque value of a fastener. The factory technical workshop manuals are VERY handy as well as Bentley's "Enthusiast's Companion" (Adrian's book). If you already have the factory manuals don't bother with "964 without guesswork".

[Glenn from Denv]

I used the "Without Guesswork" book as a reference for the torque values. Its a little handier to have in the workshop than the factory manuals because of its form factor. Also, I acquired the factory manuals after I already had the "Without Guesswork" book.

[ChrisBennet]

Thanks guys. I guess I'll stick with the factory manuals.
-Chris

[AFJuvat]

Physically, the biggest difference I've seen as far as removing the engine is the PS system that needs to be disconnected before you drop the motor.

Otherwise, Waynes book will give you a good steer in the right direction. The motor isn't that different from the earlier motor. Aside from the PS and the twin plug most of the really big changes were in the intake system. Fortunately, you can remove that as an entire assembely.

AFJuvat

I have the workshop manuals, and the two bentley books. I've found they each have their advantages and disadvantages. The Beantley books make it a lot faster to look things up, and is in a "friendlier" format than the workshop manuals.

AFJuvat

[Don Settergren]

Thanks for all your advice - my confidence level is extremely high. I can't wait to crack that case!

Now if only the parts and tools were on sale... HA!

[ChrisBennet]

I'm currently building up my first 964 motor and I can think of a few differences between a 964 rebuild and the earlier motors I've done:
- 964 wrist pin clips are a b**ch. The P9500 tool makes them easy though.
- I could install earlier piston rings with just my fingers but I needed one of those articulated ring install tools for the 964 rings.
- You need to be careful not to let a rod flop around in the case and damage the case to cylinder sealing bevel. I slipped some hose over the rods to keep that from happening.
- You need to make a chain tensioning tool to put pressure on the chain while timing the cams.
- You need to replace the 964's twin distributor belt.
-Chris

[schubee]

I used Wayne's Rebuild book, the factory manual, and the PET. I could only give you one advice from a rookie wrench.....PATIENCE! There's no word to explain the satisfaction when you turn the key and the roar of the engine awakens the entire neighborhood. Sorry Wayne, that was one advice I didn't take from your book!