I need your help. What else should I change if engine out?

[C11BRA]

Hello all.

Long time no post. Sorry. Head down with work & pandemic survival. Oh. And a new home. And a new puppy. And. You get the idea.

So, C11BRA has been stored at a mates garage whilst we move home & he expands his garage facilities. Time has come that we now are ready to give the car some planned maintenance.

I have always wanted to replace some or all of the coolant pipes that we all know are a weak link. Mine are not the worse I've seen but they are definitely on their way. At the moment, the plan is to replace all rubber and hard plastic pipes (except the small diameter vent pipes).

I am going to use the opportunity to fit new radiators too as they looked pretty scruffy when I replaced the AC condensers.

I am going to replace the clutch to slave pipe. (My 996 one failed in Spa)
And I'm going to replace all 4 hard brake lines where they meet the flexible hoses. These are all starting to corrode.

One rear pipe (ideally) requires the engine to be removed and due to a pin hole in an AC pipe that goes over the engine, I've decided it's coming out!!!!

So, what else should I do whilst it's out? Oil separator?

Any advice would be appreciated.

Thanks in advance.

997.1. Carrera 2S 3.6 with later engine number.

(I'm going to avoid the clutch & IMS rabbit hole at the moment).

 

[MaxA]

Are you considering any work on the actual engine once it comes out, or are you concentrating on the auxiliaries?

Once we removed the engine on the Mini, we replaced a lot of those hard to access seals and gaskets that might leak or weep oil ie rear main etc. And I've since then re-done the valve cover gasket. Next I'll be pulling the front end off for some preventative maintenance on the supercharger and I'll replace the water pump, thermostat; hopefully I'll even get the baffled sump by then as well, since we're in the area. Once you go down the rabbit hole...

 

[C11BRA]

Not planning to work on the engine.

I will be looking for corrosion issues. Like the fuel rails that corroded on my 996. That was a real challenge to replace with the engine in place.

 

[C11BRA]

Big day today. Engine coming out. I hope.

Bought 2 new radiators off EBay this week. Branded Mahle but they now own BEHR. OE spec? BEHR on end caps. Less than half Porsche price.

 

[C11BRA]

Quick update.

Engine out. Went pretty much to plan. I quite enjoyed it tbh.

I have a nice list of preventative jobs.

I will update the thread over the weekend.

Here's some photos.

 

[jonno_]

Nice work.
Whilst its out I'd certainly be checking brake, a/c pipes, coolant pipes, AOS, fuel rails.

Certainly makes sense to give it all a thorough going-over whilst its dropped :thumb:

 

[sja360]

Have you sprayed that front impact bar ? Sorry just mine on the 4S isn't painted.

 

[C11BRA]

Have you sprayed that front impact bar ? Sorry just mine on the 4S isn't painted.

I haven't painted it. I'm always surprised how clean it looks when I take the bumper off. No idea why it's painted gloss black. Maybe new when the GT3 kit was fitted??? :dont know:

 

[C11BRA]

I'm replacing the front diagonal braces (due to unsightly corrosion). About £40 each. So not worth the time to clean up.

However? The rear diagonal braces are bit more substantial and are more like £150 each. Can't believe Porsche don't even powder coat parts like this. The black finish came off so easy. It must be just paint. Huh? Why?

Anyway. I've stripped off some loose corrosion and tomorrow I'll remove much more then prime & paint with a much stronger finish.







Ooooooh. Some of the pipes arrived today. Water, brake, clutch & AC pipes.

 

[Luddite]

I am full of admiration relative to you taking on the task of removing and replacing corroded items that ideally should not exist on a high quality machine.

One other possible issue that might be worth a bit of attention is that of the exhaust nuts bolts and set screws that hold the system together, and seem to corrode well ahead of the rest of the system..? Though be warned it seems highly unlikely their removal might be a simple task with a set of sockets or spanners, and may end up with the need to buy specialist tooling to drill out and replace what seem likely to end up as at least a few sheered off fixings..?

Perhaps worth a bit of research before you go shearing those all important fixings.. :?:

 

[C11BRA]

I am full of admiration relative to you taking on the task of removing and replacing corroded items that ideally should not exist on a high quality machine.

One other possible issue that might be worth a bit of attention is that of the exhaust nuts bolts and set screws that hold the system together, and seem to corrode well ahead of the rest of the system..? Though be warned it seems highly unlikely their removal might be a simple task with a set of sockets or spanners, and may end up with the need to buy specialist tooling to drill out and replace what seem likely to end up as at least a few sheered off fixings..?

Perhaps worth a bit of research before you go shearing those all important fixings.. :?:

I did spot a few rusty nuts. I did change most to titanium last year when I overhauled the system.

I'm still shocked that the struts are so poorly protected.

 

[maldren]

Looks good, what's the finish you used?

 

[C11BRA]

Looks good, what's the finish you used?

After primer. I use a textured paint designed for lining the beds in pick up trucks. It's amazing. So tough.

Overspray is messy though. So don't spray inside.

Giving the radiator carriers some love next.

Radiators looked scruffy. But essentially ok. Looking forward to installing new BEHR units to re-painted carriers.









Cleaned and sand blasted. 80% better.

 

[C11BRA]

Radiator carriers now zinc primed and tough black coated. Full strip down of fans & cowlings to clean.

New radiators fitted.

New pipes & interconnects are at the workshop so these will be added before install.











Remembered to black the top & bottom edges. I don't like seeing the silver through the grilles. Makes negligible impact on thermal properties. Many radiators are black from factory.



Rusty bolts replaced with Stainless.

 

[CB911C4S]

Great job - thanks for sharing the updates. It makes me want to do it as well - if only I had a garage!