Engine Going Back In

[lucittm]

Thanks!!! to all of the folks that helped me during my recent clutch replacement (Patrick Motorsports) that turned into a partial engine rebuild (Wayne, Steve@Rennsport), turbo replacement (Turbodriven.com), wastegate overhaul (911nut), engine mount replacement (Bob), and countless other upgrades, repairs, fixes, and cleaning (boeing 717).

Hear are some pictures of the engine going in. My wife (100lbs) and I did this, so there is no excuse for you guys putting this off.
Left side

Right side


The engine sounded so sweet when it came back to life.

The high points:
1. My wastegate diaphragm was pinched in the mounting cup so the Andial 1.1 bar spring was doing nothing and I was at full boost ? all the time. (This was the reason cylinders #5 and #6 had broken rings and failed the compression and leakdown tests.
2. All the gaskets and o-rings were hard as rocks and that is what contributed to the oil leaks.
3. I hate Porsche for using carbon steel exhaust fasteners, I broke four of them upon removal and got all of them out except one (thanks Walt). I replaced all the exhaust head studs and nuts with ARP SS fasteners. I also replaced the exhaust pipe flange bolts with ARP SS products.
4. I learned how to time the cams. Since I only pulled one cam, I had to do that one from scratch. Someone suggested that I am really looking to match the two readings so I checked the other side as well. It was off by 2mm.
5. Walt at Competition Engineering did the head work (since I was in there) and they came back to me beautifully clean with new guides and seals but otherwise unmolested. Expensive but worth every penny.
6. My turbo turbine rotor was trashed from foreign object damage at some point in its life? Tim at Tim's Turbos helped me to diagnose the problem. I was able to find the last K27 "cartridge" in the USA, and so now I have a working turbocharger.
7. After the engine came out, one of my engine mounts was at an odd angle. It looked like the picture in Streather's 964 PEC book on page 121. Then I found out that the turbo mounts are not listed in the PET (thanks Glen at Pelican Parts). It seems that 964 turbo mounts have a stud that is 10mm longer than the N/A cars. Luckily, the dealers stock the turbo mounts because they can go "both ways" and they are more desirable for track events since they are stiffer.
8. I removed the auxiliary air injection system and installed the plugs in the heads. Since my check valves were a rusted mess, I should have higher exhaust pressure going back to the turbo. Why is there no listing for a cap to replace the line on the CAT/CAT bypass?
9. There were 19 incorrect or missing parts on my engine from the cover on top of the transmission to bolts, screws, washers, and clamps. I am proud to say the engine is as close to factory spec as it can be.
10. I did add the RSR seals in the rocker arm shafts and the LWF and clutch of the RS/GT3. I felt that these changes were what the Porsche engineers had in mind all along.

Thanks,
Mark