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Like many people, I find my Cayman underpowered on the track, which is almost exclusively where I use it. Rather than doing things the easy way and swapping in a 3.8, I just picked up a very cheap 3.4 core with one severely damaged cylinder, which I'm going to build into a 4.0L plus engine with a bunch of goodies including a 991 GT3RS intake plenum and runners which I have sitting here. Hopefully I'll have this done in the next six to nine months, but life typically gets in the way, so it will probably take me a couple of years. I'll post pictures/updates as I have them.
Keep us updated on progress. Seems like this is happening more and more with some of the Caymans getting up there in mileage. Some interesting swaps happening. Mine is at 99,985 right now!
My car is an '09 Cayman S with a PDK, full suspension, larger tires/wheels and a bunch of other stuff. It has ~40K miles on it, and still runs great. I'll keep my current engine as a backup when I put the new engine in.
This replacement engine is also out of an '09 Cayman S, and I got it for very little money, but don't know how many miles are on it or anything else about the car it came out of. I finished tearing it down last night, and will post more pictures over the next couple of days. The #2 cylinder is destroyed, but that's fine since I'm going significantly oversize with new wet sleeves anyway. There is some wear on the bearings, but nothing concerning, the crank looks fine, etc., though I haven't measured anything yet. I may need one cylinder head where a couple of valve heads broke off and got beat around.
I don't have a lift, and am just working in my garage. I don't have a specific budget for the project, but am doing the project as cheaply as possible. I will do everything myself except probably the cylinder heads and the machine work on the block, though I haven't ruled out boring out the block on my small vertical mill.
My car is an '09 Cayman S with a PDK, full suspension, larger tires/wheels and a bunch of other stuff. It has ~40K miles on it, and still runs great. I'll keep my current engine as a backup when I put the new engine in.
This replacement engine is also out of an '09 Cayman S, and I got it for very little money, but don't know how many miles are on it or anything else about the car it came out of. I finished tearing it down last night, and will post more pictures over the next couple of days. The #2 cylinder is destroyed, but that's fine since I'm going significantly oversize with new wet sleeves anyway. There is some wear on the bearings, but nothing concerning, the crank looks fine, etc., though I haven't measured anything yet. I may need one cylinder head where a couple of valve heads broke off and got beat around.
I don't have a lift, and am just working in my garage. I don't have a specific budget for the project, but am doing the project as cheaply as possible. I will do everything myself except probably the cylinder heads and the machine work on the block, though I haven't ruled out boring out the block on my small vertical mill.
Yes you can replace the cylinders. You can bore them out. We converted my 3.6 to a 4.0 by this process using a version of our reknown aerospace alloy Nikasil Plated cylinders.
The oil spray jets are a nuisance and some simply remove them but we re-fitted ours successfully.
At present we have no immediate plans to offer this service as too booked up with Gen 1 re-manufacturing and oversized engine conversions - but meanwhile the 4.0 PDK Gen 2 is an absolute joy to drive (espcially since I left foot brake and unlike the Gen 1 tiptronics the throttle remains open).
I will try and attach a few photos to show how a full wet liner replacement can fix damage like this because the whole bore would get machined out anyway. One photo shows an old 944 3 litre turbo Nikasil plated alloy liner (LHS) the Gen 2 replacement (centre) and the Gen 1 on the RHS - showing the reduced coolant depth in the gen 1, the ribs on the outside that increase coolant surface area and hopefully a couple of photos that show the finished block (form our 4.0 litre engine). Before anyone complains this is selling (by the way) we are not offering this service yet for Gen 2 engines (too busy with Gen 1) so I am just demonstrating issues that others might like to resort to when choosing solutions.
Of course wet liners also have better heat transfer and much stiffer bore roundness as any tube inside another tube is less stiff and less stable.
Now to try and add photos.
Baz, thanks for your posts. That is the approach I'm going with, and reading many of the detailed posts you've made on this subject have been helpful as I've done my homework and planned my build.
I'll post up the sleeve designs I'm going with after I finish drawing them up and settle on a design with the manufacturer.
Do you have any advice on removing the oil squirters? I'm planning on going back in with new ones, and potentially converting to screw in BMW squirters or something easier to deal with.
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New Engine Project
