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Part 2
What basic rebuilding parts and consumables will I need? Will I replace all the standard hardware and fasteners? I will need new bearing shells, timing chains, chain support rails etc. Where am I going to buy these from? Will I go cheap and buy from the aftermarket and risk buying out of spec parts or will I buy direct from Porsche agencies. My advice is to do both. Buy the most critical parts like bearing shells from the dealer and the less critical parts like chain guide rails from the aftermarket.
Get answers to all of this before you even start. Planning is so important. Make up a schedule of work to be done and in what order. I am going to remove the engine on day X. I will remove the gearbox and clean it on the same day. Another day I will disassemble the exhaust system and intake. I will inspect each part and note any repairs required and add these to my rebuild plan and make sure these are covered in my budget. Included in the preplanning should be, what can I do to help lower the outside labor costs? Once I have the parts back and the assembly starts, do I know what I am doing? Do I understand how to measure the case main housing, can I measure bearing clearances, do I understand how to check the piston to valve clearances, do I understand how to time the cams? Now is the time to understand all of this. Too many “jump” into this with excitement about rebuilding their engines without any clue of what they are doing or about to embark on.
Now, the engine and gearbox are removed from the chassis, the disassembly part begins. What tools are required, and do I have all the tools required? Can I store the gearbox somewhere? Do I have the correct engine stand? Do I have an area to store all the Intake, sheet metal, exhaust system? Do I have a clean work bench space?
Keep the workplace clean. Clean after yourself especially after removing the exhaust system and Intake. Keep the floor clean. Keep the tools clean. As you make a mess, clean it. You will feel so much better working in a clean environment. I have seen pictures of tools left lying over the floor, an oiling mess on the floor, such a toxic place to work. Keep it clean and clean as you go. Only have the tools required to perform each job out, clean and put them away as you finish each job.
Now you have the top end apart, inspect the parts. Now is the time to collate the schedule and budget you have made to see if you are under or above what you have planned for. Do as much cleaning as you can yourself and do it as you remove the parts. Storing clean parts is way easier than dirty oily parts. In your planned budget you will have some timeline on when you will send out parts for cleaning and any finishing.
The major parts now under inspection will be the Camshafts, rockers, and cylinder heads. Probably most DIY’s will send out the heads for repair. The camshafts should be carefully inspected now for pitting on the lobes. If they are to be reused, and in great shape, clean them, oil them and put away in a safe place. Do not drop them as they will break into two pieces very easily. Inspect the rocker arms for wear. The bushings will probably show wear, especially on the thrust side of the rocker arm. Do the rocker arm pads show signs of wear? How do the timing chain gears look? Often these shows signs of chain misalignment and need replacing. Now is the time to check your budget for these parts or add to it. A running total will be easier to budget than a hefty unknown amount at the end.
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