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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon May 13, 2019 6:03 pm    Post subject: Reply with quote

What a great find. I'll get one of those. Thumb

MC
 
  
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steve r
Monza


Joined: 26 Sep 2011
Posts: 211



PostPosted: Mon May 13, 2019 6:13 pm    Post subject: Reply with quote

No Problem.

Hope it hasn't hijacked your thread too much, maybe we need a separate one for Cup Cable install info?
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue May 14, 2019 6:53 am    Post subject: Reply with quote

I have started to dismantle the engine by removing the wiring loom and the intake manifold. The manifold appears to be slightly lower than the 996 one and definitely thinner, it does look like it isn't likely to flow as well, which makes some sense.

I never cease to be amazed at the packaging on these cars. The way the wiring and pipes loop around each other but are still easy to remove, with connectors which just fit through the spaces required.

With the wiring and the intake removed it looks very much like the power steering, air con and alternator, and associated brackets, are exactly the same between the two cars, so they can all be moved across. The AOS is different, but I already have a scrap one of those on the spare engine.









MC
 
  
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TurboRob
Newbie


Joined: 18 Feb 2019
Posts: 35



PostPosted: Tue May 14, 2019 12:22 pm    Post subject: Reply with quote

MisterCorn wrote:
Yesterday I picked one up which allegedly has problems with second gear synchros.




How does one go about sourcing a second hand gearbox, and what's the going rate? My 996.2 is about to click over 150k miles, would like to buy and rebuild a replacement box and park on the shelf for if/when required...

Cheers, Rob
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue May 14, 2019 12:34 pm    Post subject: Reply with quote

You keep your eye on eBay and on the forums and wait, then beat me to it Very Happy . Be aware that you will need access to a serious press, around 100 tons, to do the work. I am yet to source one at a sensible price so will be looking to local engineering companies to do that part if I can't get one, it is only a couple of gears I believe. Not something I really want to do TBH, I much rather do it myself, but I'm not looking to pay £6k for a press!!

I will of course be writing up my exploits on here, so you can see what is involved.

MC
 
  
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TurboRob
Newbie


Joined: 18 Feb 2019
Posts: 35



PostPosted: Tue May 14, 2019 1:14 pm    Post subject: Reply with quote

OK thanks, will keep an eye out. Please let me know if you have one or see one you don't want and I'll jump straight on it.

Have access to a press of that magnitude through work so no worries there. Is there a 'rebuild kit' in existence with all the required bearings and shims, etc?
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue May 14, 2019 1:25 pm    Post subject: Reply with quote

I have seen some bearing kits, but I would take each one as it goes and see what it needs after taking it apart. It sounds like a fun job to me.

MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 6:50 am    Post subject: Reply with quote

Air con compressor, alternator, power steering pump, alternator, and a few sensor moved across from the boxster engine to the 3.4l scrap engine. The 3.2l is getting to the stage where it can be dismantled now. It looks like one of the AOS bolts might be a little challenging.







I will have to note the differences in the drilled and tapped holes on the 3.2l and 3.4l head so that the additional required holes can be added at the machining stage.

MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 8:15 am    Post subject: Reply with quote

Having a quick look to see if the throttle bodies will fit, it looks like there is a fighting chance.








MC
 
  
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NedHan79
Nürburgring


Joined: 08 Nov 2018
Posts: 443



PostPosted: Wed May 15, 2019 12:15 pm    Post subject: Reply with quote

If we already have independent throttle bodies, is there any way to run them separately with their own trumpets? I’m guessing it would need stand alone management. Heat soak would obviously be an issue but it would sound awesome.
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 1:28 pm    Post subject: Reply with quote

Yes there would, the thinking behind the central plenum though is that it can then run an air filter in the same place as usual and have a decent cold air pickup, it will be able to benefit from the torque tuning by using the control flaps in the plenum, and it will look a bit more OEM.
I don't think the management requirements will be very different though as although we could run an AFM, we don't plan on doing so.

MC
 
  
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crash7
Montreal


Joined: 28 May 2011
Posts: 592



PostPosted: Wed May 15, 2019 2:50 pm    Post subject: Reply with quote

Martin,

Slightly off-topic, where did you land on brakes? Are you sticking with the Cayenne calipers upfront, or going in a revised direction?
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 3:09 pm    Post subject: Reply with quote

crash7 wrote:
Martin,

Slightly off-topic, where did you land on brakes? Are you sticking with the Cayenne calipers upfront, or going in a revised direction?


I have a set of 380mm front / 350mm rear PCCB disks and 997 GT3 PCCB front calipers which I am working with. Currently waiting for adapter brackets to be made up, so I'll report back when they are finished. I am assuming that the rears will be the same offset as now, otherwise new brackets will be required there as well. I haven't got any rear calipers yet and would want new ones to match the front PCCBs but want to finish the front soon.
These brakes will probably end up on my C2 if the PCCBs fit properly.

MC
 
  
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crash7
Montreal


Joined: 28 May 2011
Posts: 592



PostPosted: Wed May 15, 2019 3:27 pm    Post subject: Reply with quote

Thumb I would be interested to see the caliper bracket that you come up with the get the front PCCB calipers to fit to the C2 130mm hole centre knuckle/upright.

Or have you changed the knuckle/upright?
 
  
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NedHan79
Nürburgring


Joined: 08 Nov 2018
Posts: 443



PostPosted: Wed May 15, 2019 7:51 pm    Post subject: Reply with quote

MisterCorn wrote:
Yes there would, the thinking behind the central plenum though is that it can then run an air filter in the same place as usual and have a decent cold air pickup, it will be able to benefit from the torque tuning by using the control flaps in the plenum, and it will look a bit more OEM.
I don't think the management requirements will be very different though as although we could run an AFM, we don't plan on doing so.

MC


Surely if you get rid of the afm you would need aftermarket management. I’ve no experience with Porsche management but I changed it in my Impreza to get more features such as anti lag but more importantly it allowed me to run more boost. Thing is, it was mafless and had to be set up live on the road. I drove and the mapper spent days scaling the fuel, ignition, boost tables along with whatever else. Without an airflow sensor there must be some sort of preset. Like I said I’m no expert but I’d be very interested in the itb route if it was doable at a reasonable cost.
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 7:59 pm    Post subject: Reply with quote

What I mean is that we are planning to run this maffless, so it will need an aftermarket ECU whether we went for a central plenum or not. In theory we could run a MAF and in that case might be able to run the standard ECU, that is something we are currently investigating and if it works I will probably run that on my C2.

MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 8:02 pm    Post subject: Reply with quote

crash7 wrote:
Thumb I would be interested to see the caliper bracket that you come up with the get the front PCCB calipers to fit to the C2 130mm hole centre knuckle/upright.

Or have you changed the knuckle/upright?


No, haven't changed the upright. These are the 997.2 GT2 calipers which have a much larger spacing than the 997.1 or 996 turbo/GT3 calipers, but a smaller piston area than the 6 piston 997.2 turbo calipers so the brake bias won't be affected aversely. With running the 380mm disks there is also more room for a bracket.

MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6947
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu May 16, 2019 6:41 am    Post subject: Reply with quote

Almost two hours in the garage this morning, making some progress on stripping the engine down. The rounded off bolt on the AOS was removed by slotting it with an angle grinder and using an impact screwdriver.





The manifold bolts looked a bit crusty, all but one came out with a single hex 13mm socket.



One was beyond it and will need a lot more work, an 11mm single hex will fit on it which shows the corrosion. I think I'll attack that when the head is off the engine.

Water pump removed, oil pump cover bolts all removed and bagged up, then the engine was locked at TDC



First camshaft cover removed. To my relief the camshaft journals look really clean.



Next up is to remove the camshafts, tappet chest, and the head.

MC
 
  
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Ghianightmare
Spa-Francorchamps


Joined: 25 Apr 2017
Posts: 278
Location: Dublin


PostPosted: Thu May 16, 2019 8:25 am    Post subject: Reply with quote

MisterCorn wrote:
Almost two hours in the garage this morning, making some progress on stripping the engine down...

MC


Now I finally understand how you get so much done... posting an update at 7:41am after almost 2 hours... you do it instead of sleeping! Fair play - I couldn’t get up that early and if I did, the kids would get up too and then I wouldn’t get anything done.

Loving the engine strip.

Did you ever consider one of the bolt induction heating tools considering the amount of work you are doing on rusty bolts? Or are do you choose the patience approach?
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Martin996RSR
Spa-Francorchamps


Joined: 08 Dec 2016
Posts: 319



PostPosted: Thu May 16, 2019 8:31 am    Post subject: Reply with quote

Those manifold bolts look brand new compared to mine.
 
  
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