Back in the garage

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Hi Errie,

Been watching your thread to get the courage to do the same to my early 2.0; thanks! Your thread will be priceless.

I have one question about the photos above, where does one purchase those red plugs to close off case openings? I've been looking for some for storage of an MFI pump and will need them when I tear into my motor.

Thanks,

Ron

Ron - PM me your adres , I have some left at will mail it to you. Bought these years ago , can not remember where.
Errie

Today I will measure the deck heights on cylinders 4-6 to make sure they are in spec. Cam timing will be done hopefully next week.

Deck heights
 

Removed right bank and tested deck heights -

4- 1.32 mm 5- 1.29 mm 6- 1.31 mm.

I tested # 1 cylinder after the machine work was done - 1.37 mm.

I used the solder method , and might be off a few hundreds.

After testing deck heights , heads and cam tower was put back and torqued down ( using oil ! ).

Hopefully I will not see these babies again for many years.

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Cam timing done using two dial indicators. Took me about 4 hours. Many helpful tips on this forum helped me getting it very close to perfect , and well within range - 2.5mm in my case.

Remember that #1 and #4 are one rotation apart , and keep tension on the chains.

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Piston to valve clearance
 

The BOOK says - after all thy have done so far , thy will test the piston to valve clearance. If they are not correct , thy have options.

Valve to piston clearance > 1.5 mm on intake and > 2.00mm on exhaust.

I never questioned the quality of work down by George and Ike.

I missed this
 

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Pulling the fan off

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And of course the bolts were not too short , the alternator will fit in a different fan housing , or in the current one if it is machined.

I will try to find a machine shop in this area that can remove 9.3 mm - which might not be a good idea.

Don't do any machining on the fan housing till you check the fan belt alignment with the crank pulley. Cutting 9mm out of the housing will set the alternator back, but might also pull the fan belt back and out of correct alignment. Did you get the wrong alternator?

Mark - to my rescue again !

I do not know. Look at the pic of the alternator in the housing.

Will take more pics and post.

The housing on the new alternator is 9mm longer than the old one. Would the best be to buy a new alternator that fits , machine the housing , or service the old one ?

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Put the fan belt on and check the alignment with a straight edge against the surface of the crank pulley. Measure the difference between the fan belt and the straight edge at the bottom near the crank pulley, then at the top near the alternator again between the fan belt and straight edge. Should not be more than 1mm difference. If it's good, then you will be in trouble if you remove 9mm later.

Just saw your pictures. I would get the correct alternator.

I guess like all others new to this , the " while I'm in there " made me make costly mistakes and questionable decisions.

The upside to this is that I have enough spare parts ( many new ) , to build another 911 engine in the future.