What else to do while the engine is out?
 

The engine needs to be dropped on my new to me 1987 911 Carrera coupe. I took it to my trusted independent shop, German Master Tech in Bend, Oregon. The starter needs to be replaced because the top bolt is rusted and too short for the mechanic to get his socket wrench on it. The mechanic recommends replacing the clutch while the engine is out. The clutch is original as far as I can tell, and the car has 98,000 miles. I am having a cat delete pipe installed and the exhaust crossover pipe replaced. I asked them to remove the following while the work is being done:

- remove A/C/hoses and parts
- remove A/C/ bracket (compressor is already out)
- remove cruise control unit
- replace rusted oil pipe under engine (since the exhaust is coming apart)
- steam clean the engine compartment, tranny, etc.
- check valve adjustment, replace leaking valve cover gasket.

Any other suggestions? I am a noobie 911 owner, and have a goal of creating a fun driver that I can enjoy an occaisional track day along with being a fun and modestly comfortable road car. Less weight and simpler seems intelligent to me. A/C not necessary where I live. Thanks!

why is the exhaust coming apart?

why would the mechanic suggest a new clutch unless the old one was slipping?

My suggestions would be to inspect and possibly replace the engine fuel lines, rear brakes flexible hoses, possibly the suspension bushings, and that's it. I would probably not even do a full drop just for that one starter bolt.

The crossover pipe was rusted and broke while the Cat was being removed. The mechanic felt that the clutch was not engaging until the pedal was almost all the way out. I've driven the car about 1200 miles without much complaint about the clutch other than it seems pretty stiff compared to my BMW's. I thought maybe it was a Porsche thing. I could not drive barefoot because it hurt the bottom of my foot to use the clutch, but no problem with shoes on. I have pretty strong legs. What's normal?

The mechanic tried to do a partial drop of the engine, but told me he could only get about 1/8" on the bolt with his socket wrench. He said something about some washers that must have been added or removed at some time in the past. Good point about the fuel lines, thanks.

may not be mentioned because you are already doing it, but I would ensure you do the gasket replacement for the oil pressure sender, breather gaskets, etc... (i.e. triangle of death)

get the 101 projects book and fix all the common oil leaks that are much harder to reach when installed. replace the sound pad if it needs it.

G-50 starter removal.........
 

Otto,

Is your trusted mechanic familiar with the G-50 transmission? The top starter stud has a barrel nut unless previous owner replaced it with a standard nut which I doubt. You need an extra long Allen wrench to get to this barrel nut out but not a socket!!!!! Secondly, there is the clutch lever that needed the updated version. If this clutch lever/shaft is still the original part, then a replacement is due. This would require an engine drop and a good time to inspect the clutch disc. Do a search and this was discussed broadly by Kevin aka KTL.

Tony

Definitely address the triangle while the engine is down, the seals are cheap and it only takes a few minutes.
Other thing that is easy to address while the engine is out is replacing the engine sound pad.
A close inspection of the fuel and vacuum lines, replace anything that is the least bit questionable.
If replacing the clutch, I went with the spring centered unit rather than the rubber disc style. Also check the clutch fork bearing to bushing upgrade has been done.
It is a slippery slope, many tasks become much easier when the engine is down, you want to take advantage but not break the bank.
Love my 87, happy motoring

Tony, You are correct about the barrel nut. It was a quick explanation by the mechanic, but it was still a problem for him. It was me who misinterpreted what tool he was using. This shop has been working on Porsches for years, and does full restorations, so I'm pretty confident they know what they are doing, but thanks for questioning it. Any other opinions about what clutch to use?

Get a line of credit :D

yeah - g-50 clutch ain't cheap.

address the clutch fork update -

How does the soundpad look? How about replacing trailing arm bushings? New shocks -= always easier with the engine out. Definitely fuel lines. Check condition of all hoses - at 98K miles chasing a vacuum leak is a pain in the neck.

I always will take a look at the top of the engine to make sure critters have not made a home there.

Reference sensors/CHT sensor - replace them if they are original.

Triangle of death that's been mentioned.

New crank seal and flywheel seal.

may as well make it count

Soundpad was almost new when I bought the car two months ago. Yeah, I have a line of credit... I was hoping to paying it down pretty soon, but it looks to be going the other way. I was hoping to purchase a lift for my garage and start to do some work myself, but the starter pooped out me last week. The car could definitely use shocks, but I was hoping to wait on those for awhile. This is very helpful...I will be going over all this with my mechanic...and I will read up on this stuff in the Bentley manual so at least I know what is going on. Thanks!

Getting a lift is the best investment. Mine pay for its self in less than 2 years.

Starter, Clutch, Flywheel, SSIs, Mufflers and so on. Whatever you buy, as a minimum the labor will cost you about the same.

Go for it, you wont regret it.

We dropped this engine to address oil leaks and ended up doing a top end, replacing the clutch, new clutch cable, oil hoses, you name it. Once you get the engine out and see all this marginal stuff you really want to replace it!
At a mimimum I would replace all the gaskets and hoses that are original. No better time and great peace of mind.

http://forums.pelicanparts.com/uploa...1371614300.jpg

oil cooler seals
fuel lines
bushings (bell cranks)
rear suspension bushes
how much money you got? :-)

Tranny mount bushings look at WEVO
Engine mount bushings

Fuel injector servicing.

Replace every rubber oil line and vacuum line.