Slipstream - May 2005

Halftime for My Carrera Part II
Photo by Ed Hughes
by Ed Hughes
As I wrote about last time, I dropped the 120K mile motor out
of my ’84 Carrera for a clutch and other miscellaneous
maintenance. This was my first time taking the motor out of
a 911, and it went pretty well, with no “surprises.”
Once up on the engine stand, I was ready to begin. I must say
the ’84 motor with its heater motor and ducting, the air box and
the A/C isn’t exactly a beautiful sight when it is in the car, but
once you get these items off, the motor starts to look like it mean
business. So, after taking these items off, as well as the sheet metal
and plug wires off of the motor, I was getting to where I could
start my work.
The first few tasks were cleaning, cleaning, cleaning and a
then more cleaning. There were many years and miles of crud to
get off before I was about to do any mechanical work. I worked
up a pretty good system that made the ordeal not too painful.
Home Depot and Lowes sell drop cloths that are very similar to a
diaper. They have plastic on the outside and absorbent material
on the inside. I would place a sheet of this under the motor and
then spray Gunk TM (liberally and often!) on to the areas I was
working on. I’d then scrub with a nylon brush and rinse with
a squirt bottle filled with water. The liquids were contained in
the drop cloth, which I changed as it became saturated. If I were
taking the motor apart, cleaning would have been simpler, but
this worked OK.
Photo by Ed Hughes
who has a pretty good internet following, re-programmed it to
optimize it to the headers I put on last year as well as our 93
octane fuel. I can’t wait to see if I feel a difference.
As I write this, the motor is all together and ready to go back
in. To complete the clutch job, I cleaned up the throw out fork
shaft, and put in a new clutch cable. I also repacked my CV joints,
installed a new sound pad in the engine compartment, and
replaced my rear brake lines as well as new plugs and plug wires.
Before - Waiting for Some Love
Since my A/C has been non-operational the last 3 summers,
I’m removing it to clean up the engine compartment. To help
round this out, I also put on a new cone filter intake to replace the
stock air box, and a heater duct “backdate” to replace the large
blower motor and duct assembly. This really cleans the motor up,
and I love the way it looks. Next weekend is the installation and
the chance to check out how my project has come out. It’s been a
lot of fun, and very straight forward. I must say that the Porsche
911 motor is pretty straight forward, and not too complicated to
work on. For a non-mechanic such as myself, I’ve been able to
figure everything out, and if it all goes back in well, and I have no
problems, it will have been a gratifying experience.
I then commenced my mechanical work, which included a
new clutch, flywheel and pressure plate as well as miscellaneous
new seals for the senders as well as the engine mounted cooler.
While the motor was out, I decided it was a good time to rebuild
my starter and alternator. The alternator bearing had a slight click
when I spun it, so it was good timing. For a grand total of $125
for the two, I think this is cheap insurance considering the
convenience. I also adjusted the valves, which could not have been
simpler. This is a job that is not too awfully complicated in the
car, but it requires a little contortion. Out of the car, it’s a breeze.
While the alternator was off, I cleaned up the fan and shroud
and painted both. I maybe should have powder coated them, but
paint is cheap, and I’ll see how they hold up. I also sent my aftermarket
chip off for reprogramming. The guy I bought it from,
22
Let the Games Begin
Photo by Ed Hughes
After - Pure Performance & Passion!