Porsche 911 (964) Turbo - Refurb/Upgrade Plans

Part Work / Parts Link Part Number Quantity Price Each Sub Total Notes
Scart Sport Exhaust silencer New parts SCA 964 4 2 1700700 Replaces right hand exhaust box
Bilstein PSS10 Suspension kit New parts Design911 48-132633 122002200 Set of 4 adjustable struts and springs
Exhaust tips New parts 1 360 360 Replacement exhaust tips
Wastegate pipe New parts SCA 964T W 2 1199199 From wastegate to exhaust tip
Shark fin rubber seal short New parts 96555929226.4652.92
Side sill rubber long New parts 96555929233.8767.74
Front window rubber seal New parts 964 541 225 00 1116116
Rear window rubber seal New parts 964 545 225 00 1160.16160.16
Scuttle panel rubber seal 6.5mm New parts 911 799 503 07/8 24.318.62
Rear bumper to body seal New parts 965 505 34 26.3612.72
Sunroof seal front (velvet) New parts 911 564 191 00 142.5242.52
Sunroof seal front (rubber) New parts 911 564 409 00 10
Sunroof seal rear (velvet) New parts 911 564 193 00 127.4127.41
Sunroof seal rear (rubber New parts 901 564 905 05 10
Front lower spoiler New parts 965 505 001 01 1295295
Gauge faces New parts F65 641 201 06 1309309
Brake caliper refurb and powder coat Work Remove snapped bleed nipple, powder coat & reseal pistons1500500
Replace all brake lines with stainless New parts 0
Powder coat lower valve covers Work 0
993 door handles New parts 2180360 To replace 964 door handles with later look
Front wheelarch mudflap left New parts 965 559 615 00 01C10
Front wheelarch mudflap right New parts 965 559 616 00 01C10
Exhaust port sealing rings New parts 930 111 223 00611.6669.96Victor Reinz or Porsche OEM
Remove air injection pump Work NA0Removal of pump as no longer used
Oil pipework from tank repair/replace Work NA0May need new lines or fasteners to sort leak
Work Brombacher 18” split rims New parts 47402960
Continental Sport Contact Tyres (225×18) New parts2115230
Continental Sport Contact Tyres (285×18) New parts2160320
Repaint body and fix rust spots Work11000010000
Sport camshaft kit New parts110001000

Main leaks are from:

  • Crankcase hardline to rubber hose joint
  • Hardline in wheelarch to oil tank
  • A number of smaller pipes

In addition, a lot of the sections have some really horrible, horrible looking fittings that, although they may not be leaking now, they sure are not going to last another 10 years of ownership.

Crankcase oil line

aka: Oil Pipe Oil Filter Housing to Engine Porsche 964 1989-94

This one is now removed from the car, we fitted the hardline to the crankcase at the same time as fitting the stainless exhaust system, years ago; it's a backdated part from an earlier 930 Turbo, as the exhaust doesn't allow clearance for the crankcase oil line to run its normal route (round the rear of the engine) and instead runs under the bellhousing. The rubber part that joins to it is clearly not original as that huge fitting on the end is not standard at all. It's likely leaked at some point in the past, has been cut and a new end/series of joints been put on.

Originally, the oil line would have run along the back of the engine, like this standard car:

Mine was somewhat similar to that, when I purchased it, but had clearly been repaired at some point:

The rubber section was retained, and rejoined to a 930-spec crankcase hard line which instead ran back under the gearbox (the 'L' shaped section connected to the pipe on the original image). This is still in good condition, so we'll re-use that.

Porsche part number: 930 207 261 12

It is item #54 on the Porsche PET Diagram (note only the non-Turbo part is shown):

Note: The above is a reference for the original part which isn't actually what we need - it won't fit with the aftermarket exhaust system. This will need a custom section making up by a hose specialist, to mate with the hardline end we're re-using, and the fitting on the next hose, below…

Crankcase oil line to oil thermostat

aka: 965 Oil Pipe Filter Housing to Stat

This connects to the rubber end of the hose above, then runs up over the top of the wheelarch, down behind the oil tank, to the thermostat just in front of the wheel, behind the wheelarch flare.

This one wasn't leaking, but one look at the fasteners on either end (above) made us think it was a no-brainer to take it off; the outer braiding had started to fray quite badly and the ends were horribly corroded.

It was quite a task to remove from the oil thermostate without removing the oiltank, but it can be done, as long as the oil tank is drained and you can remove both the rubber hoses from the oil tank to the engine bay (the two short sections around 10-15cm long), as you need the space these make once removed.

Porsche part number: 930 207 254 05

It is item #46 on the Porsche PET Diagram:

Note: I believe the above part number is correct, but all descriptions list this as either “965 Oil Pipe Filter Housing to Stat” or “964 Oil Pipe Filter Housing to Stat”. Neither is true as this pipe doesn't go anywhere near the oil filter housing. I think this stems from the fact that the Porsche parts diagram only shows the non-Turbo oil lines, which has a remote oil filter at the top of the wheelarch. The Turbo engine is totally different and has the filter on the right hand cylinder bank.

Wheelarch hardline to oil tank

aka: Porsche Oil Pipe to Oil Hose on Lower Oil Tank Fitting … OR … Oil Pipe S Bend

Fairly simple one:

This runs from the oil tank to the series of hard lines and rubber lines on the right hand side of the crank case. The pipe itself has gone porous from a number of pin-holes along its length.

It is item #24 on the Porsche PET Diagram:

Porsche part number: 964 207 250 15

90 Degree hardline to S Bend

aka: 964 Oil Pipe Oil Tank to Oil Line … OR … L Bend

Short section, and though it isn't actually leaking, it's pitted, just like the leaking pipe above is. So no chances taken, replace this one too.

It is item #28 on the Porsche PET Diagram:

Porsche part number: 930 207 257 11

Complete Parts List

Parts list for the oil line leaks:

Plus possible new rubber hoses, as the old ones are checked, and new hose clips.

We fitted a full stainless exhaust system and decat many years ago, it has held up well, but I've always beena bit disappointed with the sound - it could be fruitier without being obnoxious; perhaps a different final silencer would help.

Also a decat for the wastegate from the turbo would be nice, finally I desperately need replacement exhaust tips; the originals have already been repainted twice and they just look a bit nasty now. Something slightly bigger, or in chrome would be good.

Suspension is the original, 1993 Boge dampers and springs, and all the original bushes etc. Although none of them are broken, it's clear that the suspension is past it… it really needs tightening up to match the cars performance.

Brake calipers are showing missing lacquer and flaking paint. They need refurbishing and powder coating - decision whether to keep them black, or go for red?

Also, at some point in the past, one of the dual bleed nippers on a rear caliper snapped, so that needs drilling out and retapping.

There's various bits and pieces that need seeing to, but the worst includes:

Rust around the front and rear window seals.

Paintwork flaking off the rear quarter window trims.

Generally the paint is looking tired, I always knew that it had a few little touch ups here and there in a previous life, but its got to a point where it needs taking back to basics, glass out, bumpers off; proper respray.

I love BBS Le Mans wheels, but they're north of £1000 per wheel, which is not even worth contemplating. Have to find an alternative; I also want to fit 18“ wheels, like the 1993-1994 3.6 model had as standard, as it's the most visually striking difference between the 3.3 and 3.6 cars.

Also: gold centres. Because it has to be.

Would be nice to give the old girl a bit more oomph.. it should already be around 350bhp, a good 20-30hp from standard via the new exhaust system and decat. Increase the boost and fit some more aggressive camshafts to get a bit closer to 400bhp perhaps?

  • blog/911_restore.txt
  • Last modified: 2020/11/07 23:02
  • by john