PaleAle

I bought my '02 on June 6. Since then I've had 2 misfire codes for cylinder 6, each 2 weeks apart. Last Sunday I drove the car at 4.5-5K RPMs for 2 short stints (less than a mile) to see if I could "clean" the plug in cylinder 6 (based on a recommendation). Unfortunately I ended up popping a coolant leak and overheated. The add coolant warning came on as a result.

Two days passed before I slowly drove the car 2 miles to my indy shop and it started to overheat again. My mechanic looked at it today and said the car started spewing liquid when he was added the last quart. Unfortunately the leak is in the middle of the engine where we can't see what's leaking. Tomorrow he starts taking off parts to see if he can get a view of the leak. Hopefully it's just a hose and not a connector or cracked water pump. If he can't see the problem and he'll drop the engine which means we won't have pressure and thus may miss something.

I'm crossing my fingers that it's a hose. However, if I have to drop the engine is there anything else that I should just go ahead and take care of? I asked my indy the same thing but want to have a little education before I agree to anything.

If anyone has had a similar problem I'd appreciate your input.

Thanks.

hodie21

Coolant fittings are number 1.

mdkelly1

You'll probably find something like this:

911mhawk

Sorry to hear, before dropping the engine they should be able to tell where the coolant is coming from. It's crowded in there but any decent shop will have a borescope

https://www.amazon.com/Best-Sellers-...rial/401578011

to see a little more before dissambling too much. Dropping vs. lowering the engine are good things to define before authorizing work; lowering is easy and cheap, dropping isn't.
I'm not familiar with your area, maybe others have good recommendations, what Indy is it at?

Good chance to get to know your car well as there's lots of things to consider when removing the engine to have fittings welded or pinned. Search that topic here to get some info, you'll see what other's did at the same time too. What you replace "while in there" depends on age/mileage/condition of components and your plans for the car.

List can be as long as your wallet is fat and goes something like:
Water pump and all coolant hoses
Air/Vacuum hoses and zip ties them
Check valves
Serpentine/tensioner
Engine mounts
Transmission mount
Clutch slave/Acumulator
Clutch, Flywheel, PP, Fork and the plastic inserts/needle bearings the shaft rides on

Hopefully you just have an easy hose to replace, get back on the road soon and can plan for the engine out stuff after summer if needed.
I did a bunch of this over the past winter when I had mine apart for a transmission rebuild.
Doing more than less while apart if you plan to keep the car and can't do the work yourself may be smart in the long run.

PaleAle

The back coolant connector snapped so it's not good. He's quoting a $450 part, some gaskets & tubing and that he has to pull the motor. Probably $4k.

Ouch.

911mhawk

[ATTACH][/ATTACH]The "back" coolant connector is pretty vague as the back of the has is the most easily accessible ones. What snapped,? What part is $450 that needs replacement? The parts are aluminum and don't typically "snap", maybe it's just a case of semantics/poor choice of words?

Is your shop and/or mechanic familiar with the 996?
People here on RL have quoted $4k +/- a little to have their engine out and the fittings welded/pinned. Don't be in a hurry on this type of project if you truly need to remove the engine. It would suck donkey to have to do it again in the near future because something was skipped in a rush to get back on the road.

The red dots in the middle of this pic are some spots I could see being a PITA, the black tubes go along the transmission and the hoses to them are towards the FRONT of the car and easy access not requiring engine out.

TeCKis300

PaleAle, don't worry...your experience is not unique for this model. And engine out is practically a right of passage.

Many of us have dealt with the coolant fittings. Either proactively or at the time of failure.

Just make sure you take this opportunity to address all the fittings while your in there, along with refreshing all the easy to access parts. Once that's done, you should have a worry free span of ownership before any major maintenance needs to be done again.

PaleAle

My Indy has had the car for over a week and just dropped the engine today. This was very cool asI spent the last week in Kauai and would have missed much of the work. I spent 2 hours in the shop just watching the work. Very cool.

I decided to go the whole 9 yards and weld all 8 connections and replace the water pump, hoses, etc. Stay tuned for the final estimate but I want this done right. Water pump and all hoses etc will be replaced.

One thing my Indy mentioned was that if I wanted to put in a performance exhaust that now was the time since the bumper is off and the engine is out. He estimates it will save 6 hours of labor. I'm OK with keeping the stock exhaust but as my wife says, "it's on sale".

I've come up with 3 options and would appreciate any input. Speed tech, Kline and AWE.

http://www.speedtechexhausts.com/ast1_012.htm

http://www.modbargains.com/kline-inn...ust-system.htm

http://www.modbargains.com/awe-exhau...-996-turbo.htm

I want a more aggressive sound but I want to pass smog in Cali and not totally **** off my neighbors as I usually workout around 5:30 AM.

Thanks in advance.

Lucid Moment

I think it is wise to have all connections welded/ pinned, as well as water pump and coolant hoses. I would probably add coolant expansion tank with updated cap, and belt?

Do you know when your clutch was replaced last? Easy job when motor and tranny are out, and save a lot on labor.

As far as exhaust goes, it is definitely not going to take 6 hours off of labor and since your old exhaust is off already, it shouldn't cost anything to swap it out with a new exhaust.

911mhawk

Nice to hear you're getting it all done and taking care of the car. Be careful of the "while I'm at it" syndrome, or, have fun with it.
Lots of things are easier with the engine and trans out, slave & accumulator, or gt2 mod come to mind.

mdkelly1

Did you take a photo of the "back coolant connector" that failed?

Road King

Sorry to hear about your misfires and your attempt to fix that resulted in a coolant leak.

I had a few missfires after I put a tune on my car a few months into ownership. Everyone said coils, and they were right. Did plugs, coils, and fuel filter at 45K miles, even though the plugs were done @ the 30K service. No more high load / high RPM missfires.

One of the indy shops in East Bay did my Kline exhaust install in 2-3hrs...6 sounds a bit excessive. I don't believe they had to remove the bumper, but they said it was tight.

I am 18 months into my Kline 2.5" exhaust. With 200 cel cats it's very quiet but does roar at WOT. With the decats, it's a little louder in the cabin and at idle, but not annoyingly so. Much louder at WOT.

Spyerx

Replace the expansion tank and all rubber hoses. Now is the time. Car is due.

PaleAle

Interesting week. Sharkwerks recommends pinning but is a 2 month wait. Alex forwarded me to The Renn Shop in Mountain View and Marvin was awesome for advice. Basically I was able to discuss welding with my Indy, Import Connection, and resolve everything I wanted to do so I ended up leaving it with I.C.

Saturday was awesome as I spent 3 hours watching them drop the motor. I'm going to replace all hoses and belts, coolant reservoir, water pump, vacuum hoses with zip tie, check valves, plugs and wires. Need to talk to him about the engine and tranny mounts (they don't look bad). The tranny has been replaced so I think I'm good there & with the clutch.

The one upgrade for me is to upgrade the exhaust, if John comes through :-). I'm also very interested in Kline.

I'm going way over my budget but I only want to do this once. If I missed anything please let me know.

Thanks to all.

Chris996

BBi Coolant Pipes....

BBi Billet Coolant Pipes $199.00
999 707 410 40 o-ring coolant temperature sensor housing+ 3 other coolant pipe housing 4 $2.75 ($11.00)
999 707 411 40 water pipe housing 8 $4.14 ($33.12)
996 106 214 70 protective ring 4 $5.13 ($20.52)
999 707 505 40 fuel black o-ring line 1 $4.14
999 707 506 40 fuel beige o-ring line 1 $8.27
999 707 364 41 oil reservoir check valve o-ring 1 $ $1.38
996 106 340 71 water pump gasket 1 $7.46
996 106 326 71 thermostat gasket 1 $2.48
999 707 315 40 water pump housing o-ring 1 $1.38
999 707 468 40 water pump housing o-ring 1 $4.14
900 123 144 30 coolant drain port seal 2 $1.04 ($2.08)
999 701 789 40 oil cooler housing + oil lines to turbo o-ring 8 $0.57 ($4.56)
999 707 422 41 o-ring oil filter bracket 1 $4.14
999 707 426 41 o-ring oil filter bracket insert 1 $4.14
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999 707 204 40 o-ring steering reservoir 1 $5.49
996-106-328-74 coolant hose 1 $27.46
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996-106-529-73 coolant hose 1 $6.39
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997-106-502-00 collant hose 1 $23.88
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996 106 318 02 throttle gasket : 1 $4.94
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996 110 318 02 throttle body seal.($6.11)
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