"Ladies and gentleman............the motor is back in the car"

Leland Pate · 09-15-2001, 04:43 PM

Oh my friggin' gawd, what a job!

I started at 7:30 am and finished at 4pm.

Here's what I did.
I started off by readjusting my valves. All were good, but my #1 exhaust rocker was jammed.

so I had to loosen the shaft bolt and readjust so it moved freely after I torqued it. All other clearances were good. So I buttoned it up and finished installing all of the minor wiring, senders, plugs, and stuff.
Then we put the car on the lift and went for it.

It took an incredible amount of effort to do this next part. We had the motor on the dolly and after getting it lined up as best we could...we started to lower the car down to the motor. I found that there is just not enough friggin' room for the rear most engine tin so we removed it and went at it again.

Still pretty tight fitting so we opted to remove the alt/fan and engine mount crossmember. This gave us a hell of allot more room to play with. As the gearbox came close to the tranny studs, we used a small jack to raise the clutch side of the motor up off the ground a bit to make it match up with the bellhousing.
As most of you know, there are four studs that secure the engine to the gearbox. the top left stud is longer than the rest so that one went in first.
After the first stud was in the bellhousing we ran into a bit of a problem. The rest of the studs weren't lining up correctly. The engine needed to be tilted to the right to mate the rest of the studs.
Geez, we must have stared at this thing for 20 minutes trying to decide what the best solution would be.
After about 4 smoke breaks we decided that we would use a second jack to bring the left side of the motor up just about 3mm. so that the other studs would slide in. Well it worked like a champ. I could not imagine trying to do this alone.
I stayed to the side (w/ both rear tires removed) and watched to see where it was binding. and my buddy Justin pushed and wiggled like a mad man, as I directed. (worked out perfectly...he broke out the sweat)
After we got all four studs in their respective holes I started to worry about the clutch release fork. When it was still in sight I tried to place it where I thought it would catch into the groove on the TO bearing. Well, I repositioned it a bit and tried pushing some more. Then we ran into some real stiff resistance....we knew we were definately hitting something. So I tried to turn the crank over to possibly realign the splines on the pressure plate with the imput shaft. This did no good.
So we pulled the motor back out just a notch and I used an inspection mirror and flashlight (looking through the hole on top of the bellhousing...NOT EASY!) to look at the release fork..it was binding... so I repositioned it and had Justin push again. This time...prefect. I can see that the fork is in the groove in the TO bearing. And then with a bit more wiggling, it mated up as pretty as you please! I tried moving the shaft from the release fork and there is barely any play in it so I'm pretty sure it's in there. Then we lowered the car until the rear engine mounts came close to the body and installed the bolts. Much easier.

So now I have the motor back in the car. I reinstalled the alternator and engine tin. Then we mounted the hard oil line and heat exchangers. <------MAJOR PITA!!!!!!!
I thought I was going to loose it a few times. We had to finaggle like 7 washers onto each stud that a barrel nut fitted to because the studs were too long.
Looks wierd but I think it will work.
And those damn hex nuts...JUST HOW ARE YOU SUPPOSED TO CORRECTLY TIGHTEN AND TORQUE THOSE THINGS???!!!
I got them as tight as I could with a stubby 13mm open end wrench. There is just NO ROOM!
Other than that I was installing breather lines, oil lines, and wiring. All that is left tommorow is the muffler, starter, fuel accumulator, filter, and attaching the fuel lines. And of course the dreaded...
Clutch linkage assembly.
I haven't the slightest clue how to reposition those clutch arms and helper spring. I'm gonna read up on it all night tonight but please...feel free to give me any tips and advise!!

Thanks again for everything guys,

Leland Pate · 09-15-2001, 05:04 PM

Here you go guys...a couple pics of the install process. I have more but I'm too cheap to actually PAY for photopoint.

Enjoy!!!!!!

http://albums.photopoint.com/j/AlbumIndex?u=951612&a=6970602&f=0

old_skul · 09-15-2001, 05:17 PM

Well, Leland, you could always post 'em over at the Porsche Owner's Gallery....

Nice job. Looks like fun. And what a GORGEOUS engine you have there!

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Mark Szabo
1986 911 Targa 3.2
1987 Escort 5-speed 1.9 RIP
The Porsche Owners Gallery

Jack Olsen · 09-15-2001, 05:30 PM

Lee, I'm sure I speak for a lot of the guys on this board in saying that we are behind you on two very different fronts.

One, we want you to come back safely from whatever (hopefully smart and precise) action the Feds come up with in response to the (idiotic and insane) attack on New York and Washington.

And, two, we also want you to get that rejuvenated engine up and running before you're shipped out. We've all been following this for a long time, and want to be sure that you get to really enjoy the thing -- both before you head off to save the Free World, and after that job is done.

What a great picture to finally see:

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Jack Olsen
My Rennlist page • My Pelican Gallery page • My Porsche Owners Gallery page

[This message has been edited by JackOlsen (edited 09-15-2001).]

Leland Pate · 09-15-2001, 05:33 PM

Thank you Jack, very much.

Now how did you get the pic small enough to post on the site directly and WHY DID YOU PICK THE SHOT THAT SHOWS THE STICKERS I REMOVED!??

I have to buy a new set...they were faded. I know it looks bad right now...
Can you post the other pic? The one with it under the car?

Jack Olsen · 09-15-2001, 06:00 PM

Done.

If you get that program Irfanview, you can shrink them. I'm on a Mac, so all the rules and programs are different.

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Jack Olsen
My Rennlist page • My Pelican Gallery page • My Porsche Owners Gallery page

Saffs · 09-15-2001, 06:03 PM

Leland,
Well done! Looks great and get those stickers - I need some too BTW!
I wish you all the best and take care....
Anthony

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'75 911S Targa
'81 BMW Alpina C1 2.3

Rod Walter · 09-15-2001, 06:58 PM

Congratulations, Leland. I know that it's been a long, hard road to get to this point but everything looks great.

Take care of yourself and your buds where ever you find yourselves. Our prayers will be with you.

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Rod Walter
'88 911 coupe

Leland Pate · 09-15-2001, 07:05 PM

hmmmmmm....

All these responses are from "non-SC" owners.
Is there some sort of a subversive plot out there?

I thank you all for your kind comments..even if you haven't "seen the light" yet.

regards, Leland Pate
owner of a '79 SC "in one piece"...more less....let's just hope it starts...

SC to the bone.

Early_S_Man · 09-15-2001, 07:20 PM

Good show, Lee!

We have more in common in that 911 engine ... in long block form, than the differences in bumpers, hoods and other bits of trim ... between the various years of the cars.

No plot ... just pride, and fun!

And, I second everything Jack said, too!!!

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Warren Hall
1973 911S Targa
1992 Dodge Dakota 5.2 4X4 parts hauler

jabb · 09-15-2001, 07:53 PM

Very Excellent....
Look good...

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Joe A.
84 911 Targa
75 914/6 3.0

pwd72s · 09-15-2001, 07:55 PM

82SC · 09-15-2001, 08:37 PM

AWESOME!!!

I think the trans and engine mating problem was probably a misalignment of the starter motor...and the starter ring...I figured that out the hard way...I am surprised you had that much trouble getting the engine in...

I a first timer and I did all of it with jack stands and a jack...

I think you should attach the tranny to the engine...don't worry your dolly will support it. the engine is much of the weight..(my dolly looks like yours)

never had to take things off the engine...

But anyways looks awesome...I am going to put my car out of comission in a couple weeks, and will be tackling probably an engine rebuild...well looks awesmoe!!!

Good luck

MJ

Doug Zielke · 09-15-2001, 08:57 PM

Lee,
Bought a small bottle of champagne this afternoon. When you fire it off, I will pop the cork and drink to the health of your new motor, and the master mechanic that rebuilt it. Salut!!

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'81 SC Coupe (aka: "Blue Bomber")
Canada West Region PCA
The Blue Bomber's Website
"If it ain't broke...we'll help you fix it 'til it is!"

makaio · 09-15-2001, 09:00 PM

Leland,

First off, be safe on whatever mission you do.

Second, I'm stoked the engine is back in the car. And the detailing you did looks great!

Third, since your car has been out of service, I never realized our cars are the same color.

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Matt Chamblin
78 911 SC

Leland Pate · 09-15-2001, 10:18 PM

Well, when the SC brothers respond....THEY RESPOND IN FORCE!!!!

82SC I didn't have the starter installed until after the motor was bolted to the tranny...I'm pretty sure it was the release fork that was binding. I'll tell you what...next time I drop the engine, it's commin' out with the transmission as one unit! That was just too much hassle.

Brian, I have tried to find the emission stickers as well as the spec stickers that go under the engine lid....no luck...if you know a source and are holding out on me I'll be pissed!

Matt, I have never seen another 911 with this particular color! That is cool.
It is listed as a specila order color in 1979. I love the way it shines when the setting sun hits it...but then again...when it's cloudy out it looks brown.

Pray that i can figure out how to re install the clutch arms, helper spring and cable. All of my books just say: "Installation reverse of removal"...WELL HELL THAT HELPS ALLOT!!!!!!!!

Bill Douglas · 09-15-2001, 10:37 PM

Leland, from a fellow '79SC owner, you did an awesome job. I'm impressed with how professional it all looks, meaning the engine and your work area. Usually when I do something there are tools and rubbish and discarded parts - ok, empty beer cans lying all around. A great sense of satisfaction for a job well done.

Matt Holcomb · Matt Holcomb's Garage

Leland, thanks for reminding me that letting an experienced wrench reassemble my motor was one of the smartest moves of my life!

Putting engines back together, especially Porsche engines, is for unusually gifted people; you are one of the select few.

Well done!

Matt Holcomb
1974 911 Carrera 2.7 Euro-spec
1975 Mercedes-Benz 280SE
Dedicated Homepage
Engine Rebuild Homepage
Porsche Owners Gallery Profile
Pelican Gallery Profile

Serge · 09-15-2001, 11:51 PM

Leland,

That engine looks IMMACULATE. Even the intake runners are shiny and new looking. Who did your rebuild? As far as the stickers are concerned, I replaced the ones I could find for my 78 SC. There are about four that are easily obtained. I think Pelican has a few, as well as some of the usual catalogs. For the emissions sticker, someone (maybe Brian) posted the drill, you have to order it from the dealer, provide proof of title, and then when it arrives take the car in and have them stick it on.

Actually, I have an amusing story along these lines. I have a second decklid, without spoiler, that I install sometimes when I get sick of the spoiler. The spare decklid is from an '88, with the '88 emission sticker. Well, last time I got my car smog tested, I had a hell of a time convincing them my car was a 78. I was there about twenty minutes, pointing to the sticker in the door jamb. Emmision testing people can be short on humor sometimes.

Congrats on getting the engine back in, and let us know how it sounds!

Roger Shadel
78 911SC

5axis · 09-16-2001, 01:03 AM

Turbo driver checking in. Great Job Leland! The motor looks beautiful, may you have many good SC miles ahead.

David Lockhart 89 turbo cab