Long-block Assembly

Starting with the #4 position (closest to the oil cooler mount), I made sure everything was clean and put a little assembly lube in the connecting rod bushing:

Connecting rod on Porsche 914 engine

 

Then, after putting my case sealant around the base of the piston (and on the spacer), I pushed the piston just far enough out of the cylinder so I could start sliding in the wrist pin into the piston:

Piston and cylinder for Porsche 914 engine

 

Now it's time to get that wrist pin attached to the connecting rod!

Porsche 914 piston connected to rod

 

And, after the wrist pin is in place, the final retaining clip is installed, followed by the oil ring.

Closeup of oil ring on a Porsche 914 piston

 

After the oil ring is installed (follow the instructions for where to leave the ring gaps), gentle pressure can be used to push it into the groove so the cylinder can be slid down and seated on the case. After both cylinders are installed, it's time for the head, some sheet metal, lifters, pushrod tubes, pushrods and rockers - that's the completion of the long-block assembly.

 

I'll make a small confession here: I'm now quite good at removing and installing pushrod tubes... on the #3/4 side, I installed the pushrod tubes before putting on the sheet metal and had to take them back off. On the #1/2 side, I was chanting, "Remember the sheet metal!" to myself - and I did remember it, but I forgot to install the lifters and had to pull the pushrod tubes back out on that side, too!

In the process, I noticed that sometimes there would be a little extra resistance when pushing a tube in if the o-ring was getting hung-up on the lip of the head. Too much force would have torn the o-ring, which would cause an oil leak, but carefully using the tip of a screwdriver to help an o-ring "bulge" slide in worked very well. Here's the best picture I could take of that bulge:

Bulging o-ring on pushrod tube from a Porsche 914 engine

 

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All pictures and text copyright 2008