1991 Porsche carrera 2 engine removal
Discussion
Hi all, just after some advice if possible. Currently working on a 1991 911 carrera 2 with an oil leak. It's running down the side of the engine so may have to take it out. I've done engine changes before but not on a Porsche.
Just wondering if anyone had any hints or tips which may make life easier. Thanks in advance
Just wondering if anyone had any hints or tips which may make life easier. Thanks in advance
It isn't a difficult job just be sure you have the space and equipment to do it.
I took the engine out of my 964 several times (3 I think in total) and have pulled many 911 engines before and since, looking back I cringe as I did it all in a normal garage with just trolley jacks and blocks.
You take engine and box out as one, the only things to be wary of on the gearbox are the bolts holding drive shafts in, these from memory are spline drive heads, if someone has used an allen key be prepared for them to be rounded, unless yours have been changed to allen headed socket head cap bolts don't use an allen key, buy spline drives. Ditto clutch pressure plate.
While the box is out it presents an ideal opportunity to do clutch slave cylinder which is a pig to do with engine in situ, also check clutch (if it isn't recently new you would be insane not to replace it, I used to shop round for mine as I was using the car for motorsport as well as a daily so it was getting used hard and for a lot of miles, first clutch change I used a full kit, the second one a year later I just replaced the pressure plate available alone from zims autotechnik in USA cheaply, the third time I used a full kit as it had covered some serious mileage by then.) as it's an easy job to do with the lump out of car. At this point you will have removed the clutch fork from the box, usually the bearings have dried up and are a mess, I would replace them (although I used to just clean them thoroughly and regrease them as I was tight for cash) as they aren't a lot of money for the problem they give if they seize up. Also make absolutely sure the clutch guide sleeve is tight, it came loose on my 964 about a year after getting it and scared the life out of me.
Engine wise, most connections are very easy to pop off, you remove the engine with most of the exhaust attached, it drops down from underneath and is ultimately just held by the 2 rear mountings, gearbox is held from the front.
It is a very very easy engine to remove, but it is heavy and ungainly, my method without a lift was to jack the car up, remove the exhaust back box (middle box will clear bumper just but needs a bit of help to clear) loosen front and rear mounts, drop off drive shafts, gearshift, remove oil/fuel/electrical connections etc. Drop car back down as far as possible, place jack on central balance point of engine and gearbox with big wooden block and undo mounts, gently lower engine down on to jack body and undo the clutch slave.
Then the fun starts you now need to get the car up in the air. A LONG WAY UP.
How you do it is up to you, I suggest not using the precarious combination of car ramps, wooden blocks, breeze blocks, a high lift trolley jack that I used to use, but you get the idea.
Slide engine out and open wallet.
I took the engine out of my 964 several times (3 I think in total) and have pulled many 911 engines before and since, looking back I cringe as I did it all in a normal garage with just trolley jacks and blocks.
You take engine and box out as one, the only things to be wary of on the gearbox are the bolts holding drive shafts in, these from memory are spline drive heads, if someone has used an allen key be prepared for them to be rounded, unless yours have been changed to allen headed socket head cap bolts don't use an allen key, buy spline drives. Ditto clutch pressure plate.
While the box is out it presents an ideal opportunity to do clutch slave cylinder which is a pig to do with engine in situ, also check clutch (if it isn't recently new you would be insane not to replace it, I used to shop round for mine as I was using the car for motorsport as well as a daily so it was getting used hard and for a lot of miles, first clutch change I used a full kit, the second one a year later I just replaced the pressure plate available alone from zims autotechnik in USA cheaply, the third time I used a full kit as it had covered some serious mileage by then.) as it's an easy job to do with the lump out of car. At this point you will have removed the clutch fork from the box, usually the bearings have dried up and are a mess, I would replace them (although I used to just clean them thoroughly and regrease them as I was tight for cash) as they aren't a lot of money for the problem they give if they seize up. Also make absolutely sure the clutch guide sleeve is tight, it came loose on my 964 about a year after getting it and scared the life out of me.
Engine wise, most connections are very easy to pop off, you remove the engine with most of the exhaust attached, it drops down from underneath and is ultimately just held by the 2 rear mountings, gearbox is held from the front.
It is a very very easy engine to remove, but it is heavy and ungainly, my method without a lift was to jack the car up, remove the exhaust back box (middle box will clear bumper just but needs a bit of help to clear) loosen front and rear mounts, drop off drive shafts, gearshift, remove oil/fuel/electrical connections etc. Drop car back down as far as possible, place jack on central balance point of engine and gearbox with big wooden block and undo mounts, gently lower engine down on to jack body and undo the clutch slave.
Then the fun starts you now need to get the car up in the air. A LONG WAY UP.
How you do it is up to you, I suggest not using the precarious combination of car ramps, wooden blocks, breeze blocks, a high lift trolley jack that I used to use, but you get the idea.
Slide engine out and open wallet.
Great post wildoliver 
[quote=ThrottleBod]Currently working on a 1991 911 carrera 2 with an oil leak. It's running down the side of the engine so may have to take it out./quote]
Have you eliminated all topside leaks yet? Theres a few areas(breathers/sensors) at the back of the engine that can leak badly and make it appear you have much worse leaks lower in the engine. Most of these items can be replaced with engine in the car so dont rush to yank it out just yet. Have a search on rennlist (http://forums.rennlist.com/rennforums/964-forum-59/) for info on this.
This is the DIY run-what-yu-brung engine removal method:
[quote=ThrottleBod]Currently working on a 1991 911 carrera 2 with an oil leak. It's running down the side of the engine so may have to take it out./quote]
Have you eliminated all topside leaks yet? Theres a few areas(breathers/sensors) at the back of the engine that can leak badly and make it appear you have much worse leaks lower in the engine. Most of these items can be replaced with engine in the car so dont rush to yank it out just yet. Have a search on rennlist (http://forums.rennlist.com/rennforums/964-forum-59/) for info on this.
This is the DIY run-what-yu-brung engine removal method:
Thanx for the excellent replies! extremely helpful! Tool wise everything is fine and have a fully kitted out workshop.
The biggest pain seems to be the loom running through the plastic casing on top of the engine, does this disconnect behind the bulkhead? It will be out tomorrow anyway. Then it's down to the customer how much they would like to spend!
The biggest pain seems to be the loom running through the plastic casing on top of the engine, does this disconnect behind the bulkhead? It will be out tomorrow anyway. Then it's down to the customer how much they would like to spend!
ThrottleBod said:
The biggest pain seems to be the loom running through the plastic casing on top of the engine, does this disconnect behind the bulkhead? It will be out tomorrow anyway.
If its the loom I'm thinking of it connects to the starter which will come out with the engine and gearbox so no need to disconnect. Just go slow on the lowering and check as you go to make sure everything is un-hooked.Good luck dude
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