Pelican Parts
Parts Catalog Accessories Catalog How To Articles Tech Forums
Call Pelican Parts at 888-280-7799
Shopping Cart Cart | Project List | Order Status | Help



Go Back   Pelican Parts Technical BBS > 1- Porsche Technical Forums > Porsche 911 Technical Forum

Reply
 
LinkBack Thread Tools Rating: Thread Rating: 1 votes, 5.00 average.
Author
Thread Post New Thread    Reply
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
czeitler386 thanks for the feedback. Yeah the fork was not loose nor damaged so I just buttoned it up and we will keep driving and see what happens.

So continued down the point of no return. Did some grinding on the yoke to clear the exhaust but then I hit the oil cooler so I just swapped it over to the other side for now. Wrote myself a note to swap it over to the correct side before I split the case.



I need to buy some proper tools. A better yoke and engine stand with the legs that let you roll the jack down the middle. Since I only had this one I had to pick up the engine with a motorcycle jack, tie it to the rafters with big ol straps and ratchet straps, and lower the jack to stack blocks until I got it to the correct height to then suspend from the straps and let me mate the yoke to the stand. Slow process but worked well.





Stuff is about to get very very real now:


Last edited by 2jmotorsports; 04-26-2016 at 12:43 PM..
Old 02-19-2016, 11:12 PM
  Pelican Parts Technical Article Directory    Reply With Quote #21 (permalink)
Registered User
 
KevinB_NJ's Avatar
 
Join Date: Jun 2015
Location: Burlington County, NJ
Posts: 148
Garage
Looking forward to your progress, so far so great! About to tackle a similar project and will refer to your thread for encouragement. Also, I now need to score a steam cleaner.
__________________
1980 911SC Black on Black
Old 02-20-2016, 05:14 AM
  Pelican Parts Technical Article Directory    Reply With Quote #22 (permalink)
Registered User
 
bourgeois911's Avatar
 
Join Date: May 2006
Location: Toledo, Ohio
Posts: 248
Just saw this on the news this morning.

19 G's to rebuild a Hyundai motor? ABC News |
I don't feel quite so bad about the dough I spend on the 911 now.
__________________
Tom
79 911 SC
Old 02-20-2016, 05:46 AM
  Pelican Parts Technical Article Directory    Reply With Quote #23 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Cooling tin is off. On to the exhaust removal.

Per the usual behavior, the "Triangle of Death" has made sure my car's self undercoating capabilities work to this day.





Got all but one of the exhaust barrel nuts out. Needs more penetrating oil and time. Is there a favorite tool for getting these hex nuts out? Some of them get kind of tough to reach and apply high torque.

Old 02-21-2016, 06:40 PM
  Pelican Parts Technical Article Directory    Reply With Quote #24 (permalink)
ROW '78 911 Targa
 
timmy2's Avatar
 
Join Date: Jul 2011
Location: Salem, OR
Posts: 7,753
Garage
John Walker recommends an oxy/acetylene torch to get it red hot and then it should come off.
Might want to degrease the area first.
The fun part of that adapter is swapping it back again after mating the case halves so you can install the oil cooler... BTDT.
__________________
Dennis
Euro 1978 SC Targa, SSI's, Dansk 2/1, Bitz kit EFI.
Need a New Wiring Harness? PM or e-mail me. Search for "harnesses" in the classifieds.
Old 02-21-2016, 11:05 PM
  Pelican Parts Technical Article Directory    Reply With Quote #25 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
A bit more progress. Did some clean up so I wouldn't catch anything on fire and broke out the heat:





I found this sweet bendy wrench in a drawer of random wrenches and it was a perfect fit for this area. Then success:





These heat exchangers seem like they would clean up pretty nicely.





I think Im going to tap out the heat exchanger outlet dents, scrub the shells back to a bright finish and apply some high heat paint to the rusty header sections.
__________________
Jose - 1983 911SC Coupe
Old 03-11-2016, 09:07 PM
  Pelican Parts Technical Article Directory    Reply With Quote #26 (permalink)
 
Now Available for Ordering:   101 Projects For Your BMW 3 Series 1982-2000  [more info]
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Came up on a couple of items that I dont need but couldn't pass up.



Then continued removing heater ducts, throttle bellcrank, fan, alternator, shroud, and wire harness.






Removed the oil cooler and found this mess:



Kind of messy around that lower seal.

Now we are here at the long block.



Already lined up a local machine shop so Im getting very antsy to open this bad boy up.
__________________
Jose - 1983 911SC Coupe
Old 03-11-2016, 09:16 PM
  Pelican Parts Technical Article Directory    Reply With Quote #27 (permalink)
Registered User
 
arbita1's Avatar
 
Join Date: Aug 2004
Location: Mahopac, NY
Posts: 2,217
Garage
Looks like you and I are at similar points in our tear down.



Sent from my iPhone using Tapatalk
__________________
Matt.

83 911SC
85.5 944 NA - Sold
Old 03-12-2016, 08:51 AM
  Pelican Parts Technical Article Directory    Reply With Quote #28 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
arbita1, I am almost to your point but my chain covers are stuck on pretty good.



Anyone have any pointers on how to get them off? Its tough to even get a plastic wedge in between the mating surfaces and I dont want to bugger them up.
__________________
Jose - 1983 911SC Coupe
Old 03-14-2016, 09:42 PM
  Pelican Parts Technical Article Directory    Reply With Quote #29 (permalink)
Registered User
 
arbita1's Avatar
 
Join Date: Aug 2004
Location: Mahopac, NY
Posts: 2,217
Garage
I used a rubber dead blow hammer and tapped them off. There are a few places I was able to get behind to tap them off.
__________________
Matt.

83 911SC
85.5 944 NA - Sold
Old 03-28-2016, 04:41 PM
  Pelican Parts Technical Article Directory    Reply With Quote #30 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
More progress. Ooey gooey chain covers off.






Tensioners and cam gears off.





Chain boxes off (not pictured).

Removed my crank pulley then tried to remove my starter ring gear on the clutch but the damn VW yoke wouldn't clear. Got tired of it and bought a correct one.



Soo much better.



Should my clutch drop out already? Its not budging.
__________________
Jose - 1983 911SC Coupe

Last edited by 2jmotorsports; 04-26-2016 at 12:44 PM..
Old 04-12-2016, 08:47 PM
  Pelican Parts Technical Article Directory    Reply With Quote #31 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Heads and cam towers off. Left bank:





Right bank:





So much carbon. I take it normal for 200K miles?

Almost there.



Grimy cylinder cooling tin.



Cylinders next.





They all look like this. Beautiful glassy grayish color. No scratches or marks of any kind. However based on the diagnosing method in Wayne's book where you check if the bores are magnetic or not these are Alusil and not Nikasil. Kind of bummed I cant hone them and reuse them due to the mileage. Ive been researching on cases where people get them plated in Nikasil anyway but right now its too early for me to make a decision.
__________________
Jose - 1983 911SC Coupe

Last edited by 2jmotorsports; 04-12-2016 at 09:14 PM..
Old 04-12-2016, 09:07 PM
  Pelican Parts Technical Article Directory    Reply With Quote #32 (permalink)
Registered User
 
SCadaddle's Avatar
 
Join Date: Jul 2012
Location: Central Mississippi
Posts: 906
A pair of suggestions:

Use a zip tie to bundle your cam sprocket with the inner sprocket and spacers from each cam together and bundle them so that the one that had the flat side facing the nut is bundled that way. Then you will know right side assembly from the left. Learned that one from a well known 911 engine builder.


As for the oil leak around the oil cooler, check this out.

Oil Leak - Help
Old 04-12-2016, 09:22 PM
  Pelican Parts Technical Article Directory    Reply With Quote #33 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Pistons next. Circlips first.



Tried to tap out the wrist pin with a small screwdriver per Wayne's book but they wouldn't budge.



With the power of the search button I made a tool to press them out.





All pistons look like this. I guess since these are the pistons that correspond to the Alusil cylinders if I either get new Nikasil cylinders or replate my old ones with Nikasil I will need different pistons, correct?
__________________
Jose - 1983 911SC Coupe
Old 04-12-2016, 09:23 PM
  Pelican Parts Technical Article Directory    Reply With Quote #34 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Since my busted head stud is what brought me here in the first place, I bought the appropriate tool to remove the rest of the Dilavar studs.



Zip Zip. Easy removal.



All bottom ones are out except for the original broken one on cylinder #4. Looks like I need a different tool for that. Vice grips wouldn't budge it.



I should note that the unbroken one on #4 as well as both bottom ones on #5 were fairly loose and easy to remove. #6 and 1-3 were nice and tight.



I plan on replacing the bottom Dilavars with stock steel ones like the upper ones so is there any point in removing the uppers? I am sending my case to a machine shop to get checked out after removing the bottom end.
__________________
Jose - 1983 911SC Coupe

Last edited by 2jmotorsports; 04-26-2016 at 12:46 PM..
Old 04-12-2016, 09:33 PM
  Pelican Parts Technical Article Directory    Reply With Quote #35 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Teardown continues.

Removed all the studs. Some of the upper steel ones had a tiny bit of rust pitting on them so Ill just replace them all to be safe. One of these is not like the others.



Clutch & flywheel out. Thank goodness the 12 point bit and breaker bar fit.



All case fasteners out.



Gentle tapping and the left case half comes off. There's the old girl's soul for all to see.





In my newb opinion nothing too exciting on the crank mains or bearings. These intermediate shaft bearings don't look too hot though.





Almost ready to pay the machine shop a visit.

__________________
Jose - 1983 911SC Coupe

Last edited by 2jmotorsports; 04-26-2016 at 12:48 PM..
Old 04-25-2016, 09:24 PM
  Pelican Parts Technical Article Directory    Reply With Quote #36 (permalink)
Registered User
 
0396's Avatar
 
Join Date: Sep 2005
Posts: 957
Congrats with your progress. As for the proper tools like the Baum, it makes life much easier. Good luck with build.
Old 04-26-2016, 05:44 AM
  Pelican Parts Technical Article Directory    Reply With Quote #37 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Thanks. Yes I have bigger issues to tackle so I dont mind getting a proper tool after a bit of struggling and realization of its value.
__________________
Jose - 1983 911SC Coupe
Old 04-26-2016, 07:28 AM
  Pelican Parts Technical Article Directory    Reply With Quote #38 (permalink)
Counterclockwise?
 
Join Date: Oct 2005
Location: Keswick, Ontario
Posts: 1,546
You'll need the stud tool to put studs back in. Money well spent.
__________________
Rod
1986 Carrera
2001 996TT
A bunch of stuff with spark plugs
Old 04-26-2016, 07:35 AM
  Pelican Parts Technical Article Directory    Reply With Quote #39 (permalink)
Registered User
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Santa Ana
Posts: 295
Garage
Disassembly home stretch.



Intermediate shaft disassembly uncovered a surprise:







Intermediate shaft timing gear is missing a tooth. Thankfully no other damage seems to be present anywhere else. After some checking with the experts Im going to replace both my crank and intermediate shaft timing gears and the distributor drive gear to be safe.

This was kind of cool to find. Safe to say no one has been inside the case in a while?





Disassembled the cams, rockers, and shafts and organized all the little bits.





Consulted with the experts again to evaluate the condition of my cams, rockers, and shafts. Ill send those out to be reconditioned after I get the bottom end put back together.

Dropped off my case, crank, and rods at a local machine shop. Now we wait and see if everything checks out ok.
__________________
Jose - 1983 911SC Coupe

Last edited by 2jmotorsports; 07-13-2016 at 07:20 AM..
Old 07-12-2016, 11:13 PM
  Pelican Parts Technical Article Directory    Reply With Quote #40 (permalink)
Reply

Thread Tools
Rate This Thread
Rate This Thread:

 


All times are GMT -8. The time now is 03:41 AM.


 
Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2016 Pelican Parts - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page
 

DTO Garage Plus vBulletin Plugins by Drive Thru Online, Inc.