Engine Rebuild - Part 1 (Feb 10)

Although I like to work on the car myself, I'm no where near enough competent (or have the facilities) to do this myself. Hence, on Monday it went into Unit 11, Warrington for Danny and Jonny to tear down. The car had multiple small leaks in all the usual places that an aging 964 engine has (timing chain covers, power steering pump, crank case nose seal, cylinder base gaskets, etc) and some leaks from breather pipes around the inlet. Therefore, I elected to go for their menu rebuild as a starting point. This includes addressing all these leaks, fitting new oil through pipes, new valve guides, de-coking the valves and cylinder heads, new piston rings, new timing chains and tensioners.

Of course, lots of other stuff crops up once the engine is out, particularly engine tins that need to be replaced or blasted and powder coated and breather hoses that have hardened and need to be replaced. Ideally, I want to have a LWF and clutch fitted but that will depend on how heavy the main bill gets! Luckily, my current normal DMF and clutch has been found to be in excellent condition and can go back in if the funds run out.

Here's the empty space in my engine bay where the lump used to reside:

The clutch slave cylinder and hose (left of next picture) has already been identified as needing replacement as has the clutch fork:

Here's the inlet and engine cowling that has been set to one side. The cowling is oily from leaking breather hoses. It's also split and some point so is going to need replacing:

Here are the first pics of the engine as it's being (quite quickly) disassembled. Obviously it's very dirty and oily at this stage:

This pic shows the rusty crank case breather hose on the right that will soon be coming off and replaced: