Engine rebuild sequence
 

Hi, I posted a last week about what shops were good for engine work, after a lot of thought I decided to build it myself, there is enough info on line that I feel comfortable doing it myself, my question is this, I looked for this info and really cant seem to find it anywhere but I want to make sure it is done right, is this the proper engine building sequence for rebuilding the block, this is of course after everything is cleaned and measured,
install crank and bearings, girdle and oil pick up
install rod bearings pistons and rings,
install upper and lower balance shafts,
install water pump and oil pump.
install back plastic cover.
install head gasket and head
install valve cover
install timing belts.

I just want to make sure I have the main parts in the correct order. If I am missing anything please let me know or if there is any advice please advise, any help is greatly appreciated.

Porsche 944 Repair Manual for 1983 thru 1989 covering 4-cylinder engine including Turbo (does not include 944S model)

This came in handy. I have two. One for inside the house and one for the garage.

Have fun!

I have the manual too, but in the overhaul chapter it tells you how to put the crank in and pistons and then that's basically it, everything else is covered in the first part of chapter 2 but there is no sequence of events on how it goes together. that's more what I am looking for.

Just take it slow. You will be fine.

Don't forget the sealer all the way around the girdle.

Slow and THINK about it as you go. Just remember NOT to install something that you're just going to have to take back off because you forgot something. There really is no real set sequence of building an engine. Some mechanics will do it one way and others a slight variation. But the general sequence is from bottom to top. Be sure to use assembly lube on ALL bearing surfaces. Don't forget to lube the thrust bearing surfaces either.

Thanks for the replies guys, I am going to assume the sealer goes between the girdle and the block and not the girdle and oil pan.

all I have left to do for disassembly is remove the pistons and the girdle and then I can start measuring everything and cleaning. every bolt I took out I put back in the block so I know where it went, when I took it apart the valve cover gasket was torn, water pump gasket was so brittle it just fell apart, the inside of the motor smells like burnt oil. main seals were leaking really bad. the inside timing belt was broke, it got wedged in a pulley but not enough to stop the wheels from spinning, it flattened out the teeth on the belt. none of the bearings were seized so that's a good sign.

Here is an older thread you may find useful.
http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/487924-project-924-s-engine-replacement.html

Glademister has previous experience as well reviving these cars and may give advice if needed.

Hi guys,

Sorry its been a while since my last post, it has been a pretty busy last year for all of me and my family, I am hopefully ordering the rebuild kit for my car next week from pelican parts. I am hoping customs gives me a break when it comes across the border. In the quote I got it say I have front balance shaft bearings and then the split ones, I can't seem to find any diagrams where the front bearings would go. My car is an 85.5. Am I missing something here or are those pieces for another style of motor. I will post lots of pics as I go along with the build, this is my first time doing a Porsche motor, I have always built SBCs.

start from the inside out...LOL

you should put the oil pump in after you install the main bearings/crank girdle.
then oil pickup/pistons/rods, then oil pan.
then balance shafts and water pump, then cylinder head, then cam housing.
then back plastic cover, then pulleys and belts, then front cover...

TIP: put the oil pump drive sleeve on the crank snout/in the pump BEFORE installing the crank front oil seal.

Thanks for the reply, I wrote all of your info down, I will follow that as I go along. I can't wait to start driving it again.

Chris,

If you haven't discovered Van Svenson's YouTube Porsche channel I recommend that you take a look at his extremely professional and detailed repair videos. He's my hero when it comes to repairs.

Here's a link to one of his engine rebuild videos:
https://www.youtube.com/watch?
v=ICsiEmAtjgU

Good luck and keep us posted on your progress!

Leo

I watched all of his videos, I learned a lot about the internals of the engine that's for sure. he knows his stuff.
Does anyone know the answer to the question about the front balance shaft bearing, I cant even see a spot where they would go on the shaft. I am going to look more in depth tomorrow.

The front bearing goes in the bolt-on front housings for each shaft, installed from the back, lightly press-fit into place.

Awesome. Thanks so much, its weird I don't remember taking them out of the housings, I will check when I go home to see if they are still in there.