Foreword Reminiscence What to look out for when buying a classic Porsche 911 About the star car - celebrity background Format of the book Chapter 1 - Preparation for Engine Removal Explains how to prepare for engine removal and the various tasks to complete prior to removal. Draining of gearbox oil and engine oil. 1. Organising & Preparation 2. Draining Oil 3. Jacking 4. Disconnection 5. Parts & Tools Chapter 2 - Engine Drop and Hoist Explains how to drop the engine and how to handle the engine once out of the car. 2.1 Engine Drop / Raising Car 2.2 Block & Tackle 2.3 Parts & Tools Chapter 3 - Top End Engine Teardown My experience in dismantling the 911 engine. Observations and a description of the parts required. Also the tools required to complete this task. 3.1 Reasons for Rebuild 3.2 Alternator & CIS System 3.3 Exhaust & Heat Exchanger Removal 3.4 Shroud and Accessory Removal 3.5 Triangle of Death & Oil Lines 3.6 Timing Chain Covers and Clutch Removal 3.7 Camshafts, Timing Chains & Heads 3.8 Cylinders & Pistons 3.9 Head Disassembly & Cam Housings 4.0 Parts & Tools Chapter 4 - Preparation for engine rebuild. New parts, used parts, refurbishment tasks and machining tasks. Costs associated with this preparation. Includes alternator refurbishment. This includes refurbishing the Continuous Injection System and replacement of vacuum hoses. 4.1 Head Restoration 4.2 Painting Parts 4.3 CIS Refurbishment & Vacuum System 4.4 Alternator Refurbishment 4.5 Sound deadening 4.5 Parts & Tools Chapter 5 - Engine Rebuild & Set-Up How to rebuild the 911 engine, including the setting of engine timing and valve adjustment. The tools required to complete this task. Carrera style tensioners and considerations. Discussion of oil leaks at the appropriate part of the rebuild. 5.1 Head Studs 5.2 Triangle of Death 5.3 Chain Ramps & Timing Chains 5.4 Flywheel? 5.5 Pistons & Cylinders 5.6 Sheet Metal 5.7 Oil Return Tubes and Heads 5.8 Rockers & Timing Chains 5.9 Timing 5.10 Clearances 5.11 Final Long Block Work 5.12 Exhaust, Fan and Shroud 5.13 CIS System 5.14 Clutch 5.15 Parts & Tools Chapter 6 - Gearbox Rebuilding The history of the type 915 gearbox. Symptoms and possible corrections before deciding upon a rebuild. My experience with this and the ultimate cost and parts required to complete this task. How to break the gearbox in correctly. Oil changing intervals and how to. Adding short shift kit. 6.1 History of the maligned 915 6.2 Symptoms of issues 6.3 Structure of the Gearbox 6.4 Parts Replaced 6.5 Gearbox Linkage Adjustment and Refreshment 6.6 Short Shift Kit 6.6 Parts & Tools Chapter 7 - Refitting the engine and gearbox How to reinstall the engine and gearbox, including fitting of a new clutch and clutch cable. Engine and gearbox mounts. Advice and my experience in doing this. Reconnection of the necessary ancillaries including fuel system and how to fire the car up for the first time. Checking fuel delivery. Setting timing, idle speed. How to break in a rebuild engine and gearbox. CV Joints. Engine sound deadening. 7.1 Joining engine and gearbox 7.2 Setting up to move 7.3 Reconnection 7.4 Firing Up Chapter 8 - Body Strip How to dismantle the car, including removal of interior. The tools required for this task and the associated parts. Includes glass removal methods. 8.1 Interior 8.2 Bonnet and rear lid 8.3 Front Bumper and Valance 8.4 Lights 8.5 Front Wings 8.6 Rear Bumper and Valance 8.7 Mirrors and Doors 8.8 Targa Hoop 8.9 Windscreen and Rear Screen Chapter 9 - Kidney and Sill Repair 9.1 The problem 9.2 Supporting Car 9.2 Cuts 9.3 Welding new parts 9.4 Primed Chapter 10 - Inner Wings and Wings Restoration 10.1 Wing corrosion 10.2 Inner Wing assessment 10.3 preparation of inner wing & restoration 10.4 outer wing restoration Chapter 11 - Painting Parts. Some considerations. Includes identifying originality. 11.1 highlights of repainting Chapter 12 - Reconstruction of the car. Includes the infamous task of re-installation of the Targa glass. Key experiences. 12.1 Bumpers and Valance front and rear 12.2 oil lines 12.3 front wings 12.4 bonnet and rear lid 12.5 Doors & Mirrors 12.6 Glass & Relevant Rubbers 12.7 Lights and Wiring 12.8 Tools and Parts Chapter 13 - Rust Prevention on a 911. 13.1 Injection map 13.2 wheel arch liners - creating 13.3 Materials & Tools to use Chapter 14 - Targa Roof rebuild 14.1 Examples of issues 14.2 Stripping the roof 14.3 Panel alignment 14.4 Refitting webbing, cotton, etc 14.5 Headlining 14.6 Seal fitting & Window Alignment 14.7 Final result 14.8 Tools and Parts Chapter 15 - The heating system 15.1 How it works and issues 15.2 Work done to restore 15.3 Alternative approaches 15.4 Parts and Tools Chapter 16 - Pedal Cluster Rebuild 16.1 Removing the pedal cluster 16.2 Restoration 16.3 Refitting 16.4 Parts and Tools Chapter 17 - Suspension Refresh 17.1 How suspension works 17.2 Symptoms of age 17.3 Shock Absorbers 17.4 Item X 17.5 Parts and Tools Chapter 18 - Refitting the interior 18.1 Parts and Tools Chapter 19 - Born Again
