What's new
Porsche 911 UK Enthusiasts Online Community Discussion Forum GB

Welcome to the @Porsche911UK website. Register a free account today to become a member! Sign up is quick and easy, then you can view, participate in topics and posts across the site that covers all things Porsche.

Already registered and looking to recovery your account, select 'login in' and then the 'forget your password' option.

Unrivalled evidence based driver training experts, CAT delivers true dynamic understanding of how your car works

997 turbo engine removal DIY - engine refresh and new turbos

Small update on this. While getting the rear brake line unions undone and ready for removal I realised that the crossover one to the OS rear wheel looks like a total nightmare to replace.

There are two pipe unions into the rear connector block (shock horror!) but the larger of the two (crossover pipe) , 13 mm is stuck fast so I am looking at options...and it's not a happy look. The corrosion is only in the 2 or 3 inches past the connector block and it's not overly bad now I scraped the paint off, but I thought seeing as I have it in bits I will replace them while the engine is out.

Well, I am deeply regretting that decision at this stage!; I know the stock steel pipes are not very flexible and it literally has to pass through some crazy places to make its way across to the OS rear wheel. Looks like all pipes have to be unbolted to stand a chance of fitting new oem one?

It literally seems to be the first thing that is fitted to the bare bodyshell.... dammit, the new lines are coming tomorrow so I will have to give it a go I think. Not good for my plans of getting the engine in this weekend! Also hoping the caliper bleed nipples undo , going to check them first!
 
Another update; well after confirming Porsche do not sell any connectors? (what's the all about then..!!) and would only sell me a new loom, the ebay shop I was directed to in my other thread happens to sell the connectors needed for the coils, 3 pin Bosch ones.

One connector was melted around the terminals, watch out for coil heatshields in bad condition as I think that was the root cause for this.

One coil connector just had a broken clip, that was an easy replacement (see pics removing its terminals using special porsche tool 0078 paperclip ), the other melted one I cut the connector off; then saw the terminals were a bit worse for wear after my exertions so decided to resolder new lead tails on. Additionally one of the wires had been hot as well so it was a non starter to use the old terminals on the new connector.


Now that is done the engine is built back up, just needs the engine hangar refitting and I will partly put the aux belt on to save a bit of time for when I have it back in.











Have new main rear brake pipes, the bleed nipples are all free on the calipers (first check I made) so although one nut is very stuck in the alloy block connector (at the rear NS of the car) I am going to have a go at getting it off this weekend and replace the brake lines and refit the motor. Will update
 
All coming together now :thumb:
 
Gazc2 said:
All coming together now :thumb:
Click to expand...
Cheers Gazc2 :thumb:

Well, I stupidly decided to 'just' replace the rear hardlines before I refit the motor. I can confirm its a nasty job if you use the Porsche lines which I did. In reality my lines were in very good condition except for some surface corrosion near the joining block and a couple of little bits deep under the OS. But seeing as I had bought new lines, just in case... I had to fit them :D

The short line (NS one) was a piece of cake. It came out of the connector block easily and was replaced easily. The large crossover line, not so much...
It was a pain on axle stands, a ramp would give a bit more wiggle room but I still think it would be a nasty and expensive job.

In the end I undid the OS rear top arm and that allowed me to get the brake line into place. At that stage it was all in the right orientation and near the correct clips so it was easy enough to clip it all up and fasten it from there. Getting it into the correct orientation was a bit like something out of the crystal maze.
The crossover line nut was well into the connector block so I cut the pipe, used a proper spanner and a little blast (very cautiously) of map gas to free it up, it came out in the end

A few pictures for posterity. Now that is out of the way, a few final prep jobs and checks and refit the motor as soon as I get chance. Also got read brake disc protectors to fit as the old ones have had it







 
Small update on this. Have been busy with work and holiday but back with it now. I fitted the motor back in, connected the coolant pipes together and pressure tested the system with a coolant tank lid adapter and pump from the kit I bought.

All looked good, held pressure nicely. Then came out the next morning to find a small puddle of coolant under the car :eek:
Cue many swear words and taking the engine back out again (took 90 minutes this time as a lot wasnt connected) so I found the leak immediately and it was , as you might guess 'deep in' so I removed Bank one intake and tightened the offending jubilee clip (wasnt quite snug enough it seems!).

After that I decided to make a pressure test kit for the engine before refitting (which I duly did using a few plumbing skills and some bits from screwfix, 22mm copper pipe and end caps and a compressor shop supplied footpump connector and backing nuts). (will post a pic). I was very tempted to do this before the refit but thought I might get lucky... it seems not :hand:

Pressure tested multiple times to 1 bar and now holds perfectly airtight for 15 minutes + so going to refit it once I have completed a few extra jobs I found!


1/ The studs for the exhaust heatshields are corroded and not full length anymore so not usable and machine screws were holding them on (fine). However I dont like bodges, so Im waiting for some nutserts and going to drill and sert them and need the engine out for this (not used them before but they look simple enough)

2/ while I wait for the nutserts and stainless bolts I am refurbing the lower suspension parts that are off the car

Hope to get the engine back in later this week and connected up and running asap
 
Well, got the engine back out again and in, pics attached of the pressure test kit I made. Refitted it last weekend and got a bit of time the last couple of nights to get it back together. Also pressure tested the system again and it held all night at 15psi which was expected but pleasing nonethless.

The underside of the car is back together, refurbed rear crossmember, ARB etc, new propshaft guibo.
Driveshafts on, fuel lines hooked up, few more bits to connect back up top, bleed the rear calipers, heatshields and exhaust on, intercoolers, liners, fluids (oil and coolant fill), then should be ready to prime it and start.







52-FA2-A3-F-151-D-4798-9-E76-619-D3-D081516.jpg
[/url]


 
Oh, also fitted a new expansion tank as I spotted some micro cracking in the common area (one was almost full thickness) and a new coolant cap for good measure.
 
Ok, time for an update. Not been a lot of time recently on this and I have been waiting on a few issues. Namely I found a leak/hole when I pressure tested an intercooler (like a pea sized hole in the core) so I have been trying to source replacement intercoolers without going to the OPC. After two sets of incorrectly fitting intercoolers, I ordered an OEM new one.

During the wait I stripped and had the intercooler cages repainted, and fitted new hardware. Also I now have the NS rear back together complete with a wheel! Hopefully the new IC turns up today or tomorrow so I can finish the other side and get it tested. Also got to add coolant, its been a bit late after work to run the compressor to get it vacuum filled, but it holds vaccum like a world champion!








 
Well, the car is back together and running sweetly I am happy to say. Will post a video at some point. Got to get the bumper on before I go chewing the tarmac but it runs sweetly; which is a nice little Christmas bonus!
Many thanks to Kozzi for the intercooler!!
Not sure if anyone else does this here for oil changes but I read best practice is to do a full drain, then put 2 litres down the oil filter centre, then the rest in the oil filler tube. I added 2 and 6 litres. Then pulled the fuel pump relay fuses x 2, let it turn over a bit, wait, turn over, wait etc until oil pressure built up.
Then fuses back in.
Car started first turn of the key and the mezger is purring, ready for some salty road driving action :eek:

Then added about just under half a litre of oil to get to max on the oil level display
 
Good effort :thumb: glad you got your various intercooler issues sorted all this hard work will be a distant memory once you get it on the road. look forward to your thoughts once you've driven it.
 
Gazc2 said:
Good effort :thumb: glad you got your various intercooler issues sorted all this hard work will be a distant memory once you get it on the road. look forward to your thoughts once you've driven it.
Click to expand...

Thanks Gazc2! Seems to be only you who diys their turbo from here..!
I do hope it becomes a distant memory, it has left a slightly bitter taste at present so its more relief that its done rather than happiness at this minute! Took it for a spin round the block earlier and it was like a rocket , boosting fully etc. Hoping it stops raining so I can take it out at the weekend for a full session as it were!
 
darkhorse said:
Gazc2 said:
Good effort :thumb: glad you got your various intercooler issues sorted all this hard work will be a distant memory once you get it on the road. look forward to your thoughts once you've driven it.
Click to expand...

Thanks Gazc2! Seems to be only you who diys their turbo from here..!
I do hope it becomes a distant memory, it has left a slightly bitter taste at present so its more relief that its done rather than happiness at this minute! Took it for a spin round the block earlier and it was like a rocket , boosting fully etc. Hoping it stops raining so I can take it out at the weekend for a full session as it were!
Click to expand...
Very good effort. Me, I have a 2007 turbo and I have upgraded the turbos but I don`t know if I will dare to take out the engine when you must for some reparation. :worship:
 
Great work DH - been a great thread to watch :thumb: I too am partial to a bit of DIY maintenance but doubt think I'd be able to work at the level you have here. Thank you for the updates - been greatly appreciated and this will be a decent diary to look back on.

I might look to swap my exhaust out early new year as a DIY project - I know where to come for some tips :D
 
Glad the intercooler work DH!!!
Get her on the road now mate.
Just for information: had my turbo refurbed and hybrid by Turbo dynamics. One of them we though was shot by the have made them both like brand new.
Just in case anyone has been told by OPC or a specialist they are shot!
 
Excellent work and glad it all is running smoothly. Always a very nervous moment turning the key after any major invasive work like this.

With regards to intercoolers, mines a 2008 and when I had the intercoolers upgraded to the do88 big pack I was surprised that the original intercoolers were beginning to rot through in places. I guess due to me using the car all year around ive thrown all sorts of weather at it. The front radiator consoles were also completely rotten through.
 
You must log in or register to reply here.

Similar threads

W
Don't keep your locking wheel nut key in the frunk
Replies
2
Views
315
911UK
911UK
Paul_S
997 Turbo Intercooler and Y-pipe Upgrade (Do88)
Replies
6
Views
863
photek
photek
thesmithsUK
964 Engine Rebuild - breakdown of work...
Replies
13
Views
585
Chief
Chief
X911
Engine mount nut
2
Replies
16
Views
959
X911
X911
Y
955 Turbo rear wishbone replacement issue.
Replies
5
Views
391
YPVS
Y
infrasilver
3.8 997 heat exchanger onto M96 996 engine, does it fit?
Replies
10
Views
1K
911UK
911UK
C
Engine Mount - Snapped Bolt
Replies
2
Views
813
CallumC
C
Porsche exhaust specialists

Latest posts

New Threads

Porsche Model Range

Porsche 911

Porsche 992: 2018- Porsche 992: 2018- Porsche 991: 2011-2019 Porsche 991: 2011-2019 Porsche 997: 2004-2012 Porsche 997: 2004-2012 Porsche 996: 1997-2005 Porsche 996: 1997-2005 Porsche 993: 1993-1998 Porsche 993: 1993-1998 Porsche 964: 1989-1993 Porsche 964: 1989-1993 Porsche Carrera 3.2: 1983-1989 Porsche Carrera 3.2: 1983-1989 Porsche Carrera SC: 1977-1983 Porsche Carrera SC: 1977-1983 Porsche 930 Turbo: 1975-1989 Porsche 930 Turbo: 1975-1989 Porsche Early 911: 1964-1977 Porsche Early 911: 1964-1977

Porsche Hypercars

Porsche 918 Spyder Porsche 918 Spyder Porsche Carrera GT Porsche Carrera GT Porsche GT1 Porsche GT1 Porsche 959 Porsche 959

Other Current Porsche Model

Porsche Taycan : (2019-0%) Porsche Taycan : (2019-0%) Porsche Macan : 2013- Porsche Macan : 2013- Porsche Panamera : 2009- Porsche Panamera : 2009- Porsche Cayman: 2005- Porsche Cayman: 2005- Porsche Cayenne: 2003- Porsche Cayenne: 2003- Porsche Boxster: 1997- Porsche Boxster: 1997-

Porsche Legacy Models

Porsche 928 Porsche 928 Porsche 968 Porsche 968 Porsche 944 Porsche 944 Porsche 924 Porsche 924 Porsche 914 Porsche 914 Porsche 912 Porsche 912 Porsche 904 Porsche 904 Porsche 550 Porsche 550 Porsche 356 Speedster Porsche 356 Speedster Porsche 356 Porsche 356

Forum statistics

Threads
124,598
Messages
1,441,975
Members
49,034
Latest member
briant1000

porsche insurance porsche parts porsche sales porsche car sales porsche for sale
porsche classic sales porsche tuning porsche sold porsche specialist porsche engine rebuilds porsche driver training porsche car sales porsche exhausts

Community platform by XenForo® © 2010-2024 XenForo Ltd. XenForo theme by xenfocus

www.911uk.com @Porsche911UK THE DEFINITIVE PORSCHE FORUM Copyright © 911UK 2002-2024 All rights reserved.

911uk.com is not associated and is wholly independent of Porsche Automobil Holdings SE, Dr. Ing.h.c.F.Porsche AG, Porsche Cars GB, its subsidiaries and offical Porsche centres. Any word, phrase or graphic that in any way resembles anything to do with the Porsche name or organisation are registered trademarks of Porsche Automobil Holdings SE and Dr. Ing.h.c.F. Porsche AG.

Back
Top