Rookie 3.0 rebuild

[Amstaff]

Well, I hope that this thread will both help someone unfamiliar with a Porsche 3.0 and serve as a reference for me when I forget how something goes back together.

I should start by thanking my brothers Gunther and Johann (you can tell we have a German background). My brother Gunther gave up racing and made me a killer deal on his 911 wide body along with all of his tools and spare parts. My brother Johann who is now could no longer work on his dream car, a 1970 911 T basically gave it to me for a song and a dance. This car will be my retirement restoration car. So now I have bug and I am trying to learn as much as I can about 911's.

Anyway, here it goes.

So, it all started with me pulling the engine to fix a few oil leaks. I am pretty good mechanically and have rebuild many big and small block Chevys in my time. I get the motor on the stand and as I rotate it I hear "clink, clink". Pull the top valve cover and nothing, pull the bottom and there lies 4 broken head bolts on the right bank and two on the left.

This forces my rebuild where I plan to pull the pistons and cylinders, have them checked and redone as necessary. Send the distributor off to have it recurred for carbs and install 964 cams. Then Install new rings and gaskets and along with a good cleanup of all of the parts get her back together and hopefully running smoothly.

So here is where I started...

Now I am pulling it apart. Started by pulling the chain cover and breaking the cam loose.


I kept all of the parts that came from the cam and strap tied them all together so that I would not forget their order.


Then pulled the tensioner, it wasn't that difficult but with the amount of pressure on it I am sure it will be a lot harder to reinstall.



The I began loosening the rocker arm shafts to remove the pins. It is 8mm on one end and 5mm on the other. Cylinders 4 and 5 had the 8mm facing the rear of the car and number 6 was facing the front. Not sure why but I will make sure they go back that way


That's all I have time for today but look for regular updates.

[Speed Buggy]

Have fun. Keep the pictures coming.

[Amstaff]

So, it's a pain to unscrew the rocker shafts so I went to Harbor Freight and bought a set of Allen wrenches with the the ball driver. So much easier!

[Amstaff]

Also, I am making use to bag and tag everything that comes off the motor

[Amstaff]

And then into bigger bags for each section of the engine just to keep everything organized

[Amstaff]

I should have mentioned earlier to block the oil tubes so that nothing falls into the motor

[Amstaff]

Tomorrow intake rockers come off, cam and maybe head and cylinders

[Amstaff]

While pulling the rocker shafts I noticed that number 4 intake bolt was kind of rusty. Any ideas what would cause this?

Picture attached

[Amstaff]

I couldn't leave it alone so I pulled the camshaft


Any idea how to tell if these are stock cams?

[Amstaff]

Chain guide pried off fairly easily

[Amstaff]

This magnet seems to be my best friend. I am sure it has saved me from dropping nuts and washers everywhere

[Amstaff]

Pulled all of the 13mm head bolts and washers but don't forget these nuts

[Amstaff]

With those last three nuts removed the head came off with minimal effort. Just a few taps with a dead blow hammer (small one)

Hopefully the cylinders will come off tomorrow so I can see how bad the head studs are

[mreid]

What is the number stamped into the sprocket end of the cam?

[mreid]

Actually, you removed the cam tower. The heads are still installed and under them you will find the cylinders.

[Amstaff]

The sprocket number is 901 105 546 02

You are correct, cam tower.

[Amstaff]

So I am back at it. I just can't stop as I am close to finishing the tear down.

Started by numbering the heads ( got it right this time)

[Amstaff]

Tried to loosen one of the head bolts but it was rounded off so I made this from a hex bit one size larger. A few quick taps with a hammer to seat it and it came right out

[Amstaff]

A few pix of the air deflectors for reference.

[Amstaff]

So here are the culprits. Hopefully they all are above the case.