Before the Engine Rebuild

The 964 had 119,000 miles on it when I bought it, so I knew then that it was going to need some parts rebuilt and others replaced. The images below are of the 964 being maintained. These don’t even include the engine pictures yet. At PCACIR events, I would normally ask other owners who they used for their car and engine maintenance. Henry Riley‘s name came highly recommended. I actually got his name first from the president of the CIRPCA.

 

Henry runs his shop from a building near Avon, Indiana. He has made some wiring changes, replaced the rotors and the clutch in my 964. He removed the engine and delivered it to another mechanic, Paul Ross, who does the actual engine rebuild. Henry not only is a tremendous source for Porsche related information but drives a 996 Carrera 4S. He also does the racing setup for the Porsche 911 model 993 of the president of the PCACIR.

 

Paul Ross is the mechanic Henry uses to do the actual engine work. He’s an x-IRL and Porsche mechanic. He can be reached at the following email address rossmotorsports93@sbcglobal.net. His phone number is 765-537-2798.

 

The 964 model came from the Porsche factory with a set of micro switches under the carpeting on the passenger side floor that prevented the top from being raised or lowered with the engine running. To stop the engine in traffic was never convenient, so I asked my mechanic, Henry Riley, to make a wiring change that now allows the top to be raised or lowered with the engine running. He wisely made the change in such a manner that it could be reversed if a need arose for the car to return to factory default settings.

 

This the rear with lid open of my 964 under the covering tarp at Riley Performance Motorwerks..

 

After the cover is removed, the empty (lonely) engine compartment is revealed.

 

On the right side of the engine are the oil supply lines, dip stick and filter. With the engine out, I am taking this opportunity to have these otherwise inaccessible areas of the engine compartment cleaned.

The silver colored cylinder under the left side hinge is the fuel filter. Just below and to the left of the filter, is the oil level sensor connector. The small yellow object above the fuel filter is the oil dip stick. The round yellow object to the right of the fuel filter is the oil cap. Next to the cap, is the oil filter. Between the oil cap and fuel filter is the power steering reservoir.

The carpeting segments from the luggage compartment are in the upper right corner of the image.

 

The left side of the engine contains the fuses. You can see the two air conditioning hoses starting in the upper center of the picture. This area will also be cleaned before the engine is replaced.

 

This is my car on jacks look at the rear. The transmission is on the floor, the tires and wheels are off with the rotors exposed. The springs and shocks are exposed. Those are my tires in the rear on the right. The front tires are closer. The wires hanging down in the foreground are from my brake lenses.

 

This is my 5-speed manual transmission. My old clutch is in the foreground on the left.

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This is my 5-speed manual transmission. The wires hanging down in the middle of the transmission is the speed pulse sender used to determine when to raise the spoiler. Just to the left pulse sender is the rear differential that hold both axels. I’m having the leaky seal replaced and some cleaning done before it’s re-attached to the engine an put back in the car.

 

This is my primary (in the foreground) and secondary muffler exhaust system.

 

This is my blower and air filter.

 

These are my two axels. The left side of each axels in this picture attaches to the transmission and the right side attaches to each wheel. The left seal on the upper axel had to be replaced.

 

This is right rear calipers and rotor. The rubber line directly above the rotor is the oil return line. On the right end of this line is the oil reservoir.

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This is right drilled, front brake rotor with the calipers removed. The spring and shock are exposed. Just behind the rotor is the wheel speed sensor. On the right, out of the picture are the oil lines, temperature sensor, cooler and oil blower.

 

These are the calipers and brake pads and shims from the front brakes. The wire coming out of the top of each caliper is the ABS sensor wire. The rubber tubing makes sure that all pads on a caliper work at the same time. The expanding spring is standing up on both calipers. The wire going from the caliper to the pads is the warning contact wire.

 

This is driver side of the luggage compartment with the carpeting removed. You can see the gas tank in the center, back. The deflated spare tire is in the fore ground with the tire compressor in the center of it. Next to it is the car battery. On the passenger side of the gas tank is the main fuse and relay panel. On the driver side of the switch box is the fuel expansion tank. The white plastic object in the middle of the right side is the brake fluid reservoir. Coming out of the rear of the reservoir is the breather hose and brake line coming out of the bottom. Just behind the reservoir and behind the blue line is the left side crash sensor. The right side crash sensor is just behind the bronze fuel tank strap on the other side.

 

This is passenger side of the luggage compartment with the carpeting removed. Just to the right and below to the expansion tank is the hose from the gas cap.

To the left of the spare tire, just in view are the ABS control unit and bleeder. Diagonally across the tire from ABD control unit is the ABS hydraulics (under the cover).

The fuel tank gauge is in the primary fuel tank to the right of the fuel expansion tank. Above it is the fuse box.

 

This is left drilled, front brake rotor with the calipers removed. Inside the left fender is the windshield washer pumps and tank. This side also contains the air conditioner condenser in front of the wheel and receiver/dryer unit behind the wheel.

 

This is left rear brake rotor with the calipers. You can make out the ridge the pads have worn into the rotor.