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Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Head dis assembly
continued

New valve guides:



Correctly sized:



There are many ways to remove guides. I thread old guilde:



Screw bolt in:


I use 911 cam housing that I bought on ebay for $60 as fixture for press:



Valve guide on the floor:



Original valve size:




Factory manual has sizing info. Most suppliers (including Pelican) supply 1st oversize valves, so no need for machining, if your head was not rebuilt before:


Last edited by perelet; 06-07-2015 at 07:23 PM..
Old 06-07-2015, 05:30 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #61 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Head dis assembly
continued

Pressing new guides in (heat head in oven, cool guide in fridge):



Honing valve guides:





Lapping valves:









Removing exhaust studs:



Use socket to put new valve seals:





rest is pretty much assembly and spacing springs by adding/removing washers. I also soda blasted all parts and pressure cleaned them. I contracted CNC head surfacing to machine shop - $120. That was only piece of work I contracted.

Last edited by perelet; 06-07-2015 at 06:27 PM..
Old 06-07-2015, 06:20 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #62 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Pistons & cylinders


Lifting cylinders:






One had broken ring:




Removing pin clips is pain on all engines:








Piston apart:



Soda blasted:




All cleaned up and dry:
Old 06-07-2015, 06:41 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #63 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Removing dilivars

Dilivars are sitting hard and won't go out without pain. You got to have right tool here - impact extractor.

There are 2 kinds - nondestructive collar extractor, it costs about $150. Other kind is what I used - it will destroy threads on studs. Not that I care! I'm not going to use them anymore:







What's left:





There's a lot of snake oil spilled about studs. You can find threads and wars about that subject. I went with 993 parts:




I made sizing guide from cooper plumbing pipe and cap:



(I have a lot of plumbing spares - had to redo bathrooms in our house).
Old 06-07-2015, 07:03 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #64 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Through bolts

You have to strip engine completely to replace through bolts seals. Good time



that's how it looks:






Use pen cup to get new seals on:


Last edited by perelet; 06-08-2015 at 07:07 PM..
Old 06-07-2015, 07:09 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #65 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
more to come, taking break now...
Old 06-07-2015, 07:13 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #66 (permalink)
 
Ari
 
Join Date: Jul 2010
Location: ND
Posts: 683
Very inspiring. Not many people would do as much of the rebuild work at home. I think my 964 rebuild budget (before I sold the car, knowing a rebuild was not necessary but tempting to do) came to 1/3 tools, 1/3 parts, and 1/3 outsourced machine shop work. You probably had all the tools already, from the looks of it, so you probably did this for 1/3 what the rest of us would anticipate spending.
Old 06-08-2015, 07:06 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #67 (permalink)
Science is not optional
 
rbogh901's Avatar
 
Join Date: Aug 2008
Location: Sunny Alabama
Posts: 1,602
HOLY SMOKES. Yes, it's been discussed many times but this has already answered some of the nagging questions I have never seen addressed. Very helpful!
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Old 06-08-2015, 11:37 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #68 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Quote:
Originally Posted by iamtheari View Post
... and 1/3 outsourced machine shop work. ...
I did brought heads to machine shop that deals with 911's to take 0.02mm to surface. That needs to be done.
My #3 and #6 cyl started to show leak. Not a lot, but leaked:



There's urban myth that if they haven't leaked for 20 years they won't start leaking now. Well, mines started. Any other pic of #3 & #6 from other 964 rebuild threads also show same symptoms.



Here's factory spec on surfacing:




Now and then I hear about shop installing 993 rings in to 964 heads. IMHO that's not good idea:

1. Rings will barely fit. There's no space on outer side, ring will be jammed in cyl head - pics below.

2. That's very costly procedure. Your heads will not be reusable with new style 964 cylinders/pistons. New style cylinders have groove for sealing ring. So next time you'll need to update your cyls&pistons - add 6x per replacement head


here are pics of 993 sealing ring and 964 head:




Old 06-08-2015, 06:34 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #69 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Fitting rings/pistons

Factory rings came in nicely labeled packaging:



Rings easily fit by hand, less chance of breaking and scratching piston:



Gaps at 9, 12 and 3oclock. Bottom part of the rings should have full seal - no gap at 6oclock. Factory manual has notes on that.

Pistons/rings can be fitted by hand, if you're doing this on table. On engine ring compressor may be more convenient:




964 Wrist pin holes match perfectly with US sized plumbing pipes, here's my tool:







Push it with matching socket. You'll feel/hear click when clip settles





Old 06-08-2015, 07:25 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #70 (permalink)
Registered User
 
Join Date: Jan 2009
Location: DC
Posts: 1,186
Garage
Great work.... thx for all the pics
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1986 944 turbo -first car
1997 993 Cab 6 speed-sold
1992 964 C2 turbo
SOLD, 911GT ,CIS, 428 fwhp 450 trq, Carrillo rods, 964 cams, TT retainers,7.5 comp 1.1 bar boost 320 ml black fuel head 009 injectors, 044 pumps, 60-1 T4/T3 dual scroll turbo
Old 06-08-2015, 07:38 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #71 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
rest of assembly
Pretty much as described in factory manual

putting heads on:




here's what digital torque reads after final 90deg final tightening of head studs:



factory recommended Loctite:



Cam housing covered with sealer:



return tubes:
factory recommended stuff:








all there:




new exhaust studs:

Old 06-08-2015, 07:44 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #72 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Cam trouble

Here's how my 4-6 cam looked like when I removed it:



My understanding is that around year 2000 somebody realized that zink in oil destroys catalytic convertors. So they mandated to oil companies to remove zink from oils.

Well after that date oils started to destroy cams on engines with rocker followers

I think outcome - use oil additive.



There's local Schrick cam place that had pair of 964 cams. Not anymore



my valet also got very lightweight after that.
Old 06-08-2015, 08:06 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #73 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Leak down test

About only test that you can while engine is on the stand - leak down. Next is to fill it up with oil and let sit for couple of nights.

Old 06-08-2015, 08:12 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #74 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Light weight flywheel

Not exactly about leaks, but I do have pics.... and installation steps

Removing double weight assembly:







Goodies:









Old 06-08-2015, 08:43 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #75 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Light weight flywheel
continued

Now, important thing to understand - total weight is not that much different

Total weights:





Flywheels compared:





Looking at advertizing - they usually mention weight of LWFW alone compared to DWFW assembly


Pressing in center bearing:





Things to note different bolt sizes:



Flywheel on:

Old 06-08-2015, 08:58 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #76 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Light weight flywheel
continued

clutch thickness for reference:

Full thickness:





to the rivet:






Factory diagram for release bearing fitting:



and real stuff:




Pressing in release bearing:





Lining up clutch and pressure plate:




bolted together:


Last edited by perelet; 06-09-2015 at 06:42 PM..
Old 06-08-2015, 09:13 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #77 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Light weight flywheel
continued

guide difference:



Lining up transmission:



Hold fork by piece of tape, as manual says:





bolted together:

Old 06-08-2015, 09:29 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #78 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Oil thermostat rebuild

Clamp cover and remove clip:



Slowly undo clamp - front cover should fall out:





replace o-ring:




Put everything back:

Last edited by perelet; 06-09-2015 at 07:19 PM..
Old 06-09-2015, 07:07 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #79 (permalink)
Oleg Perelet
 
Join Date: Jul 2010
Location: Escondido, CA
Posts: 180
Garage
Oil tank rebuild

Oil tank & pipe paint stripped:





Epoxy painted:



Painted:



Oil filter housing coupler aluminum washers were pretty bad:





One expen$ive oil ho$se (also pain to fit!):



All fitted:

Old 06-09-2015, 07:30 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #80 (permalink)
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