Engine rebuild..... big "whoa!"

Well ok where do I begin...
Today, I just about finished up the CIS system that will be going back on my '79 3.0.
Totally degreased, cleaned, polished runners, installed new wiring loom over old harness, replaced Warm up regulator, Cold start valve, new runner sleeves, injection boot and 6 new injectors. It actually looks fairly presentable now. I'll post some pics in a couple days or so.

Ok, so much for the update...

So what's up with the "whoa" portion you ask???
Weeell, I opened up my rebuild kit today, out of curiosity, and was very disapointed with my findings.
I don't know how these rebuild kits usually come but this one has several bags of gaskets, o-rings and washers in one rather large box.
Some of these bags are labeled, some are not. The problem is that there are some things I recognize...but others I don't. And unfortunately there doesn't seem to be any organized grouping of parts (there exhaust gaskets mixed with O-rings and vica-versa).
Well all of this has me very confused.
A couple or the small bags have Factory part numbers. I would very much appreciate it if someone could help me out with tracking these part numbers down. They are all small flat washers but I'm not sure where they go. Here they are: (900.123.115.30, 900.031.014.30, and 900.031.011.30)
If anyone can at least point me in the right direction about these small washers I'd appreciate it.
Ok as for the rest of the "mess" like I said, some of the items I know where they go and some I don't. To compound the problem, I have found a couple pieces that obviously go to the CIS system. The teardown I did on my CIS system was more less external, so I didn't use anything out of the rebuild kit except the O-rings for the injectors. So now either way I am looking at having left over parts when I am done and I don't like to even think of THAT!
Like for instance, there are some green... and, some red O-rings that go to the oil cooler or to the oil pump, but my old ones were black so how do I know which ones go where..)
I can take pictures of the stuff (mainly different size washers and O-rings) I am concerned about. If anyone would be willing to help identify some of this stuff for me I'll mail 'em a beer.
Thanks for listening to me ramble.

This is definitely going to sound half-ass, but the way I went about rebuilding my engine was to compare what I had in the rebuild kit to what was in the books as well as what came out of the engine...it might be too late for you to compare what came out of the engine, but you can kind of match some of the gaskets and what not to parts that are attached to the engine. Not helping you, I know, but just telling you my experience.

Lee,

Maybe you should get the parts catalog microfiche for your car. Generally, but not in all cases, the dimensions of the individual sealing rings are given in the description. Also, the gasket set listing has a listing of all of the seals and gaskets in the set.

Is there a brand name stamped on the cardboard backing of your gasket set?

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Warren Hall
1973 911S Targa

Leland,

I'd recommend the same as Warren. A microfiche for your car is really handy for parts I.D. You can get one from Pelican (or eBay). You, of course, need PEL-613-821 for your 79 SC.

http://www.pelicanparts.com/cgi-bin/autocat/load_page.cgi?page _number=1&bookmark=2&model=911M&currsection=documt

The Porsche Parts and Technical Reference for years 74-89 is a handy quick reference also (PEL-000-147). For $12.50 thru Pelican, it's a fair price. It doesn't always have all the part numbers you need but it's a good thing to have when you can't get to the microfiche viewer. Call around to some schools or municipalities. They usually have old stuff like microfiche readers just lying around collecting dust. You can find the readers on eBay also. The parts microfiche comes in a large (6 x 8) size, but you can still use it in the small (4 x 6) machines. You just have to flip the microfiche around alot to get where you need to be on it.

As far as the seals for the oil cooler and the oil pump, they are the same size for both the pump and the cooler (a small one and a large one). The green ones are made of DuPont Viton and are very durable. I think you want to use those in the most important place- oil pump. The red ones are silicone and are also good. I guess use those on the oil cooler. I took brown/orange/red ones off my oil cooler and the ones I rec'd from Porsche were the green type.

900.123.115.30 is number 38 (the two seal rings around the banjo fitting) in the diagram. Manual says it's a 8 x 11.5mm sealing ring- quantity = 2.


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Kevin
87 Carrera coupe


[This message has been edited by KTL (edited 05-02-2001).]

There are just so damn many tiny washers that I just don't know where they go!
There is a felt washer that I have deduced must either go somewhere in the CIS system or maybe in the distributor...
There are several different size copper washers...some of them must go to the oil pressure switch, tensioner line banjo fittings, thermotime switch...etc. GOD I WISH I HAD A GARAGE SO I COULD JUST LAY EVERYTHING OUT AND START DEDUCING!
Whew, ok... well I am just VERY uneasy about ending up with left over parts that "I am just hoping" aren't for my particular engine or go in the CIS.
I counted the little blue O-rings that go on either side of the case through bolts... 26EA...so they didn't give me any extra.
BUT!... there are what looks to be 3EA camshaft gaskets and seals! It makes no sense to me.
The case gaskets are all Original Porsche gaskets ("Rienz"?) but I am just not happy with the way it is organized. HOW HARD WOULD IT BE TO LABEL THE DAMN BAGS WITH WHERE THEY GO OR WHAT THEY ARE USED FOR??!!
Akk! Not happy...:S

Try the picture above.

The only copper rings I recall when reassembling all sorts of lines and so forth on my 87 were:

one biggie for the oil sending unit

other biggie for the oil tank drain plug

I do recall seeing a little felt-looking washer in the distributor shaft (under the rotor, in the shaft).

Sorry, that's all i've got. 87 info. probably isn't much help for you.



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Kevin
87 Carrera

Kevin, you did help me very much, thanks.

This do you recall if the rebuild kit you used included washers for stuff like the engine shroud and random sheet metal attachments?
On a related note... Good News!!!!
I was able to take the twisted mess that once was my engine sheet metal (twisted and bent badly from the engine drop incident)and really straighten it out nicely...
Some sanding and a couple good coats of High temp. paint and you'll never know

I'll post a pic of my engine shroud and polished fan assembly here soon.

thanks guys,

Lee,

Unless they chnged things for the SC, eight of the 12 x 16 mm aluminum sealing rings go just for the cam tower oil line fittings and plugs ... two to go under the adapter that bolts to the cam tower on each side, and four for the banjo fittings, two per side, then two for the plugs at the forward ends. I know you will figure it all out! Good luck!

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Warren Hall
1973 911S Targa