965 Engine Removal checklist....

[boeing 717]

965 ENGINE REMOVAL STEPS

This is the procedure i went through to remove my 965 engine. I followed The 964 enthusiast companion book along
with the porsche workshop manual as should you. Everything listed here does not have to be done exactly in this order...
this is just how I did it because i had never done this, so its probably not the most efficient way.
This is a BIG job but not a hard job. Just kind of intimidating, but as you get into it you find its pretty straight forward.
Make sure and buy ziplock bags with labels and place all the nuts and fasteners and such in those bags and label where they went
Also take pictures. Any time you unhook some wires make sure you know how they were connected to begin with, which sometimes i forgot to do.
I didnt use any special tools but you will need all the normal stuff. Get a Breaker bar... that was essential many times. Also some universal flex sockets
came in handy many times. Also a fluid extractor, jack stands, ratchet extensions and i needed 3 jacks to do this. I used two 3 ton jacks
and one Sears ATV jack for the engine. Also you will need a dolly of some sort to rest transmission on.

1) Disconnect negative cable from Battery

2) Remove rear wheel well covers

3) Disconnect flex hoses from heat exchangers

4) Remove plastic transmission cover

5) Remove Rear bumper
a) 3 screws in each fender well
b) 2 allen bolts hold bumper on, Very hard to break loose use a breaker bar
c) Remove electrical connection from right tail light housing by removing grommet.
d) Be careful bumper is heavy

6) Remove final muffler
a) 4 bolts
b) 1 strap
c) had to use crow foot wrench to get to nuts

7) Remove Waste gate
a) 4 nuts
b) 1 air line

8) Remove intercooler
a) A few hoses plus electrical connections, refer to 964 companion book for a good write up
of this. Although not difficult. Take pics of electrical or mark which wires went where.

9) Remove AC compressor lay aside on fender with towel to protect.

10) Remove Electrical housing cover in left side of engine.

11) Remove Electrical Harness from left side of engine
a) 4 multi plugs to remove, connected to housing with grommet
b) had to cut zip tie
c) There were also 2 unconnected plugs apparently not needed

12) Remove Airbox
a) 3 screws
b) 3 hoses , 1 hose goes to left side into fender well, disconnect at airbox and at left bulkhead.

13) Remove Fuel hoses From left side (3)
a) 1 to Accumulator
b) 1 to Filter
c) 1 general Fuel line
d) Caution against spillage, wear glasses
e) Counter hold fittings needed large wrenches 19 mm

14) Remove ez69 airhose
a) bottom plug on ez69 is connected towards the engine to another wire that is connected to the flywheel sensor. Disconnect the two wires and leave plug in ez69, check your connectors mine on the flywheel sensor was completely gone.

15) Disconnect O2 sensor plug left side of engine near bulkhead

16) Disconnect plug from belt tension sensor

17) Disconnect Power steering hoses
a) suck out fluid first
b) disconnect hoses from pump (dont lose copper washer on one of the hoses)
c) have rags and pan under car

18) Disconnect Three oil breather lines in right front bulkhead area

19) Disconnect hose from right aft engine area out of fan housing that goes to right blower inlet.

20) Remove Hose from (exit) top of exhaust heater box. Left side.

21) Disconnect Clutch slave cylinder ( two 14 mm nuts)

22) Disconnect CV joints at transmission, transmission in gear, park brake on, Needed breaker bar. Tie Wrapped drive shafts to shocks after removed.

23) Disconnect and remove Rear Sway bar. Disconnect nut and bolt from sway bar drop links first. Required breaker bar.
Then remove 2 nuts from bushings.

24) Disconnected Bolt from shifter coupling

25) Unhooked wires from starter, 3 wires plus one ground wire partially hidden, keep track of where each wire went, had to use flex socket for ground.

26) Drain Oil

27) Disconnect Right hard oil line in right rear wheel well

28) Disconnect breather hose from left blower fan that leads to engine fan housing.

29) Remove Center tunnel cover and fuel pump cover

30) Disconnected throttle cable at the pedal, remove the clip by popping it off the stalk then slide pin out of ball joint head. Then pop balljoint off.

31) Disconnect main braided Oil line at thermostat. Use thin 32 and 36 mm wrenches.

32) Place jack stand under engine and support it. Balance point is at the rear (Toward front of car) of engine around the bell housing area.

33) Place a dolly with wooden support under the transmission

34) Remove 6 bolts from transmission cross-member, transmission will slowy come down onto dolly. Do not do this while laying under the car.

35) Remove two engine cross-member nuts and engine should be sitting on jack.

36) Slowly jack up car stopping to make sure nothing is still attached.

37) rear of car (without bumper) needs to be around 36 inches off floor to roll engine out.



Now you can go from this...



To this............



Have Fun....

JERRY

[911nut]

Jerry, great thread. I may be dropping my engine this fall.
Did you make any mods to your powerplant?

[boeing 717]

Thanks Paul, i had posted last night a second part with pics to every step then the forum said i can only post 10 pics so i couldnt do it. I didnt make any mods other than the turbo oil line, just a major service and a few things that needed to be replaced as well which took me pretty far out of my budget..... along with alot of cleaning and making it look nice again. But its tip top now.... assuming it runs when i get it all back in.

JERRY