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'04 Carrera C4S M96/03 DIY Engine Rebuild

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Old 07-06-2018, 04:42 PM
  #31  
Coopduc
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Was that a Fram oil filter I saw?

Oh, the humanity ....
Old 07-06-2018, 05:16 PM
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LOL - yes, it is, but that was a fresh filter I put that on after I drained out all the oil and removed the Bosch one that was there.
I didn't want anything from the filter to drain back into the case after got it on the stand and turned it over.
Old 07-06-2018, 05:18 PM
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This is the filter that was on there, and the one you want to use with the IMS adapter:
Amazon Amazon
Old 07-06-2018, 05:29 PM
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Closeup of piston from #4 cylinder


And #6
Old 07-06-2018, 05:35 PM
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Ok, thats going to be it for a while.

I'm off to Mt Hood for a week of skiing and hopefully when I return my cylinders will be back and I can start the assembly process.

I didn't document this as much as I had hoped to - tough to grab your phone and take photos when you are wearing nitrile gloves and covered in oil.

For assembly though, this should be much cleaner so hopefully I can do a better job at that part.

More to come in the next weeks...
Old 07-06-2018, 06:31 PM
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strathconaman
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Subscribed. Loiks good so far. Are you getting the crankshaft runout measured?
Old 07-06-2018, 07:06 PM
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Yes, and thanks for the reminder on that. I actually did measure the axial play before I disassembled the crank carrier assembly, and will also do this after the sub-assembly is put back together.

This is the tool I used (thanks again Harbor Freight). Mount it on the crank carrier, push the crankshaft all the way to the opposite direction of the flywheel and then zero the indicator.

Then pull the crank outward and measure the distance. Mine measured at 0.052.
Here is the excerpt from one of the workshop manual PDFs' I referenced earlier.


Last edited by OutNSpace; 07-06-2018 at 07:37 PM.
Old 07-06-2018, 07:37 PM
  #38  
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I hope you mean 0.052mm and not 0.052 in. That HF tool has an inch scale.
Old 07-06-2018, 07:41 PM
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Correct, I converted it from the .002in reading to .052mm
Old 07-07-2018, 10:11 AM
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Great post and smart move going ahead with the rebuild now and doing it yourself is a great way to get even more personal with the m96. Is scoring typically more prevalent on the 456 side, if so, why?
Old 07-07-2018, 10:40 AM
  #41  
wildbilly32
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Originally Posted by GTsilber
Great post and smart move going ahead with the rebuild now and doing it yourself is a great way to get even more personal with the m96. Is scoring typically more prevalent on the 456 side, if so, why?
More knowledgable will drop in, but I've read: yes 456 side more common and related to some increased forces on that side due to engine design. But, what do I know...just enough to be dangerous!
Old 07-07-2018, 03:03 PM
  #42  
Charles Navarro
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Originally Posted by wildbilly32
More knowledgable will drop in, but I've read: yes 456 side more common and related to some increased forces on that side due to engine design. But, what do I know...just enough to be dangerous!
The piston pins are offset in the factory pistons. It is theorized that the offset is not optimal on the bank 2 side since Porsche opted to use one piston for both sides, meaning one bank (2 in this case), doesn't have the correct offset.

They did this on the Cayenne V8 as well and eventually came up with a piston that was specific for the Cayenne/Panamera that used bank specific offsets. In fact, the same piston is used between the six and eight cylinder engines.
Old 07-07-2018, 04:02 PM
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Charles, when was this change made?
Old 07-07-2018, 08:04 PM
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Great thread. Looking forward to more pics.
Old 07-07-2018, 11:12 PM
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Originally Posted by wildbilly32
More knowledgable will drop in, but I've read: yes 456 side more common and related to some increased forces on that side due to engine design. But, what do I know...just enough to be dangerous!
Originally Posted by Charles Navarro
The piston pins are offset in the factory pistons. It is theorized that the offset is not optimal on the bank 2 side since Porsche opted to use one piston for both sides, meaning one bank (2 in this case), doesn't have the correct offset.

They did this on the Cayenne V8 as well and eventually came up with a piston that was specific for the Cayenne/Panamera that used bank specific offsets. In fact, the same piston is used between the six and eight cylinder engines.
very interesting, had no idea there were different piston pin offsets for bank 1 and 2. How much deviation in the offsets are we talking about, thousandths of a mm? Do you know if the 997.1 has the same issue as I believe borescoring is also quite prevalent on those engines.


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