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NickHappy
Nürburgring


Joined: 27 Apr 2014
Posts: 451
Location: W.Sussex


PostPosted: Mon Sep 09, 2019 8:15 pm    Post subject: Reply with quote

Gazc2 wrote:
Your not talking to yourself Thumb pretty sure I`m not the only one wathching this with interest and admiration,having spent the weekend wrestling rusty nuts and seeing some of the issues you are coming across the more age related issues were going to find with these cars unless you keep on top of them not a huge revelation I know but a timely reminder they need a bit of looking after.


Absolutely this ^^^^ Great work - Not sure I’d have the balls to go this far!! although I’m up for some DIY maintenance.

Please keep the updates coming Thumb Thumb
_________________
997 turbo Manual.
996 turbo Manual. ex.
 
  
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Cossers
Newbie


Joined: 25 Sep 2015
Posts: 7



PostPosted: Wed Sep 11, 2019 10:18 pm    Post subject: Reply with quote

Great read and great to see someone actually have the nuts to work on their own car rather that be too scared to drive it because it will go down in value!
Fantastic, love it and I’m for sure going to work on mine when I eventually get my mits on it!
 
  
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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2086
Location: Darlington


PostPosted: Thu Sep 12, 2019 10:54 am    Post subject: Reply with quote

DarkHorse, great work and a very informative write up.

I never went as far with my work, which started out as a water pump issue which I foolishly ignored when I was buying the car. Glad to see you've replaced the pump, it's not the gasket that goes on them its the drive bearing/seal that starts to weep and whilst it's not hugely critical it's just plain annoying.
I got my pump from Autodoc and it was a Pierburg which by chance is what was fitted to my car from new.
The coil packs are an issue as Beru have changed the design of them. They now have a a thicker body than the originals and as a result the fixing bolts don't rebate into the pack they sit proud which means that on the drivers side the pack nearest the turbo fouls the actuator. The only solution is to fit an original Porsche coil pack as they still have the old style packs. I got 5 of the new ones from D911 and they also sourced me a Gen Porsche one so that I could get the actuator on. TBH 2 of my original coil packs were in perfect condition so I could have probably used one of them, the other ones were split and rusted so went in the bin.
As for plugs I think I went with Denso Iridium, those or Bosch should be good
I'll attach a picture.
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 



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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 108
Location: under the car


PostPosted: Fri Sep 13, 2019 6:15 pm    Post subject: Reply with quote

Thanks Eastern Jets, the coil on mine near cylinder 6 has a melted look to the back of the connector plug, so as you did I am replacing the set. Managed to order the Beru coils off ebay for half the price of the OPC but have ordered the original one from Porsche and its due on monday. I have bought the NGK iridiums? never had an issue with NGK plus before so hopefully they should be good to go!

As far as progress goes, the pipes are all removed and bonded and the engine is starting to go back together (more pics to follow). I am going to try and get a few hours on it tonight, what a way to spend a friday night Dont know


Whoops, forgot that oring, managed to source a viton one from a local specialist








I realise all engines will be different, but it seem the ones that have caused the issues are mainly the one on the front coolant bracket next to the water pump, and the one on the RH bottom side of the 4th picture down. The fitting next to the thin one that feeds the turbos with coolant (or returns it from them )

That would tally with the tightness of the fittings. Some were extremely well in and I regretted starting to heat the one in the second pic from bottom (under PS pump on top coolant manifold) as it was a swine to get out . Removing these and reusing them is quite comitting as once you have applied heat to the epoxy you have to continue!!

Anyway, will post more progress pics as I get them. I have also seperated the EGR valves (secondary air valves I think porsche calls them) from under the intake manifold, and have cleaned any carbon out from them. There was a fair bit.. pics incoming

It is the cleaning up that takes the time, fitting new parts is the nice bit.

**tonights update, both heat exchangers fitted with new orings, and various other tedious items.

Next job trying to get the old turbos off round 24..

Cheers

Last edited by darkhorse on Mon Sep 16, 2019 12:37 pm; edited 4 times in total
 
  
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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 108
Location: under the car


PostPosted: Fri Sep 13, 2019 6:23 pm    Post subject: Reply with quote

NickHappy wrote:
Gazc2 wrote:
Your not talking to yourself Thumb pretty sure I`m not the only one wathching this with interest and admiration,having spent the weekend wrestling rusty nuts and seeing some of the issues you are coming across the more age related issues were going to find with these cars unless you keep on top of them not a huge revelation I know but a timely reminder they need a bit of looking after.


Absolutely this ^^^^ Great work - Not sure I’d have the balls to go this far!! although I’m up for some DIY maintenance.

Please keep the updates coming Thumb Thumb


Cheers NickHappy! Will keep them coming for sure!
 
  
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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 108
Location: under the car


PostPosted: Fri Sep 13, 2019 6:24 pm    Post subject: Reply with quote

Cossers wrote:
Great read and great to see someone actually have the nuts to work on their own car rather that be too scared to drive it because it will go down in value!
Fantastic, love it and I’m for sure going to work on mine when I eventually get my mits on it!


Excellent, cheers Cossers Thumb
 
  
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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2086
Location: Darlington


PostPosted: Fri Sep 13, 2019 9:15 pm    Post subject: Reply with quote

Fitted the Denso Iridiums in to my Boxster and the difference was noticeable straight away. Idled better and accelerated much smoother, they get my vote.
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 
  
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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 108
Location: under the car


PostPosted: Mon Sep 16, 2019 12:46 pm    Post subject: Reply with quote

Replaced all plugs and coils, existing plugs were a bit carbonised (will have been running rich due to the turbo issues I imagine) but all looked well. Checked bores for good measure and all looked perfect. Next issue is the turbos came with no studs and I only just found out yesterday Surprised ; my fault for not taking them out of the box and looking but such is life. So, OPC order 677 is on it's way to me tomorrow all being well.

Removing the old turbos was quite enjoyable (cathartic) in some ways! The flange face on the exhaust manifold had some minor pitting on one bank when I seperated it and the old turbo (and its invisible gasket), so I am hoping the gasket seals ok; if there is any leakage from it I will have the lovely job of replacing the exhaust manifolds and their bolts.
I would do that when the cars running though so the engine can be brought up to temp, indeed I may well ship it off to a local good indy as they have all the kit in case anything snaps, will probably work out cheaper than buying a stromski jig and all the other items. The bolts look reasonable, certainly they still look like bolts anyway, if a little rusty on a few of them. All being well it will be a non issue, but I am prepared if it needs to be done.


Will update once the studs have landed and the turbos are installed. The neverending story continues...
 
  
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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2086
Location: Darlington


PostPosted: Mon Sep 16, 2019 6:54 pm    Post subject: Reply with quote

You shouldn't have any issues removing the bolts on the metzger turbo, they aren't the same set up as the other cars which have studs and nuts.
Mine came out very easily, like you I was terrified of something snapping but when I took the first one out I realised they were a different bolt.
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 
  
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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 108
Location: under the car


PostPosted: Mon Sep 16, 2019 9:57 pm    Post subject: Reply with quote

easternjets wrote:
You shouldn't have any issues removing the bolts on the metzger turbo, they aren't the same set up as the other cars which have studs and nuts.
Mine came out very easily, like you I was terrified of something snapping but when I took the first one out I realised they were a different bolt.


Thanks, I remember you saying this previously. I would be interested to see the state of some others that people have had them removed without issues?!

If I recall correctly the bolts are 13mm for most of them, but some have shrunk somewhat to nearer 12.5 or 12mm. I sincerely hope they come out without issue; but it's something I will probably let an indy deal with because the engine needs to be back in the car to get it up to temperature, and on the offchance one snaps, they will already have the methods and tools to get them out! If I ended up doing it I would be welding a nut on any snapped ones to get them out (if there was enough protruding) , but I will phone them and see how worried they sound!

Would be great to hear from someone in the trade with these cars about if 997 t bolts normally don't give issues?

Can't get back on it until the weekend due to work committments but hope to get the motor ready to go back in then..
 
  
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