[apex]

thanks for the follow-up - yes - the consistent advice I'm getting is that stainless and aluminum - is a bad idea. especially when glycol is involved. *if* I can get those darn studs out, i'll be replacing with a M6 x 45 oil pump stud.

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[apex]

With apologies for not keeping my own thread alive - thought I'd report that I actually started the car yesterday. Woohoo!

Here's the list for the last six weeks or so:

• head resurfaced via RSBarn (barely - didn't need much)
• valve guides
• exhaust valves
• everything cleaned and spiffed up (doesn't count for much, but makes me feel good!)
• gaskets (head, manifolds, etc)
• timing belt, balance belt
• belt rollers
• timing tensioner stud
• timing chain
• variocam pads, o-rings, etc
• bolts, pressure washers, etc for cam races, valve cover, etc
• re-set cam timing
• front seals and races
• distributor rotor and cap
• cleaned... all the carbonized crap from pistons, manifold, head
• new - used - timing gear cover
• water pump
• thermostat
• water pump studs
• a few exhaust studs
• all coolant hoses
• coolant reservoir
• new stainless hose clamps everywhere
• heater valve
• throttle body seals
• oil separator, dipstick o-rings
• connector rubber boots - all the two-and three- connector ones
• generator harness rubber caps, misc rubber and plastic bits...

Heh - somehow putting it all down here doesn't seem to do justice to the process. In the words of a friend of mine, I feel like I just finished cleaning the Grand Canyon with a toothbrush.

I can't tell you how good it was to hear the ol' in-line four come back to life! er... after I sorted out the plug wires properly. [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img] But she's runnin'. At the moment all that is left to sort out is a coolant drip at the junction of throttle body and intake manifold. Drat. But not so bad - at least I can get to that from the top.

Here's some pics - nothing y'all haven't seen before - ha! the wiggly wire bit shot compares my home-made special variocam tool to the one I subsequently borrowed from another 968 devotee.

   
   
   
   
   
   

almost forgot... remember the rusty water pump studs from the head of this post?

   

well this is what makes a 968 owner feel good - check out the "after" picture! Amazing what one can accomplish with a scotch-brite pad, pb-blaster, seven days to squander, and a propane torch...

   

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[flash]

that's how clean a job should look - nice going

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[PorscheDude]

Great work!!
It's very rewarding, huh?

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[benspeeder]

I ENVY YOUR AWESOME SKILLS!!!!

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[apex]

Thanks for your kind words. My skills are far from awesome, but my tenacity might be. Ha.

Good news tonight: the coolant leak was only a loose clamp on the top of the throttle body. Drip. Drip. A turn of the 7mm and all is well.

Ran the engine up to temp - oil pressure good, coolant temp right on the money, exhaust header still smokin' off the excess anti-seize, lifters mostly settled in - though one is still kinda tappy. We'll see if it quiets down. And the car looks GREAT hunkered down on the ground after having it's nose in the air for so long. Looks like it's about 1/2" from the pavement by comparison! :-)

Still haven't taken it out on the road - tomorrow, with any luck.

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[blue968]

Were did you get the cam dial tool???
Did you write up a DIY??

Thanks

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[Cloud9...68]

Blue968 - Thanks for bumping this thread. I had forgotten about it. As our cars age, and as people belly up to install Flash's new supercharger, those of us contemplating R & R'ing the head ourselves will need all the collective wisdom of this board for tips on what to do, and what pitfalls to avoid. This thread has some great pictures to help with the job.

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[apex]

Sorry about the delay in replying - I'm not checking in as much as I used to.

Blue:

The dial indicators are standard issue - paragon sells them but I found two for about half the cost on ebay - exactly the same make and model.

The dial indicator holders I ordered from Baum tools - my nose is still bleeding from what I paid - but I had to have the real McCoy [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img]

My belt tensioner tool was purchased on the side of an interstate exit like something out of a cop show - from a retiring porsche mechanic selling off his tools.

You asked in a PM about pressurizing the variocam - you need to do this using the special porsche "tool" after removing the oil j-tube - the cams are indexed with the piston in the "up" position. This little fitting I borrowed from a 968 friend and hooked it up to my cheap air compressor.

The factory manual covers all this in good detail - I also culled a lot from posts here on the forums.

As I said the job is not technically difficult - ha! but one's definition of "technical" will vary. It does require perseverance, precision, and bravery coupled with a facility and experience with typical mechanics tools.

Let me know if you have any additional questions - post them here. I am far from the most experienced person reading these forums. What I don't know others certainly will.

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