Originally Posted by Mother

Tippy you have been in the turbo world to long.....996 just thought I would refresh your memory.

Originally Posted by Tippy

If Dharn does a full write-up with pics, I vote for "Lifetime Membership".

That is definitely worthy.

Originally Posted by Tippy

If Dharn does a full write-up with pics, I vote for "Lifetime Membership".

That is definitely worthy.

Originally Posted by Tippy

I just want to get mine back together.........I need a nice amount of $$$$$

Originally Posted by Dharn55

More details on this later, right now i am having too much fun driving the darn thing.

Originally Posted by Tippy

If Dharn does a full write-up with pics, I vote for "Lifetime Membership".

That is definitely worthy.

Originally Posted by Dharn55

I actually ended up dropping the engine five times. The first to find the problem. Second when the pulse sendor turned out to be bad and I could not get it out. Third when the first expansion plug blew out of the camshaft. Fourth when the replacement expansion plug blew out, Fifth when the replacement camshaft had its expansion plug blow out. Got it down to a science now. Also, after the first time i only put it back together far enough to start the engine.

More details on this later, right now i am having too much fun driving the darn thing.

Originally Posted by Dharn55

Well about 11 months after I first discovered the intermix on my 2000 996 C4 Cab, and 2 ½ months after starting to drop the engine I took the first real drive today. Put about 50 miles on the car and everything seems fine. Total cost was about $2,000 in parts and repair of the cracked head (this included some misc parts unrelated to the cracked head) and a lot of hours of labor (but these days I am working pretty cheap).

I guess I will feel better after I put a couple of thousand miles on the car, but I am thrilled to be back in the driver’s seat of my 996 again. I had forgotten how much fun it is to drive this car, especially with the top down. The whole process of tearing down the engine, finding the problem and fixing it was quite an adventure, with a lot of side roads taken. But the final outcome seems to be good.

So those of you who have an intermix problem, TAKE HEART! When mine first happened I was told by many sources, on the boards and mechanics that the only fix was a new/reman engine. Well that is really not the case. I will do a longer post later recapping the whole process, but just wanted to let people know that the car is fixed and back on the road.

I also want to thank several people who helped and consulted on the project.

First, thanks to Doug Donsbach, who has a “twin” crack in the head of his car. We commiserated and he gave me help in fabricating tools, and the picture of his crack helped me find mine.

Thanks to Jake Raby at Flat 6. Jake is an incredibly nice guy, who has an unbelievable knowledge of these engines, and was extremely generous with his time and advice. I can’t say enough nice about Jake.

Also, a big thanks to 99firehawk, a tech with a lot of knowledge who was helpful in many ways. His time and help were really appreciated.
And thanks to Jeff Clark at Sunset Porsche. I have been getting my parts from Jeff/Sunset for several years and they are great.

Thanks to John Edwards/Costa Mesa R&D. They did the head repair and valve job on the 1-3 head. John knows the problem with the heads and has experience in fixing them. He was quick and very well priced to do the work.

Also thank to Rick and Ron at Valley Tool & Mold in Gilberts, IL who did the tapping and plugging of the cams. The expansion plugs on these proved to be a major challenge, but should never be a problem again.

There were a lot of others who helped and commented but I can’t name all of them.

So I AM ON THE ROAD AGAIN. If anyone else needs some help with their intermix problem I would be glad to help as much as possible, I have developed a little bit of expertise in this over the last few months.

Originally Posted by Manho Kim

Hi,

I found your posting here, and I desperately need your advice for my 1999 Porsche Carrera which has an intermix problem. What is the dust step to look for ? My mechanic could not find crack on the engine block. The coolant is going into the engine oil and the Temperature goes high after about 10-15 minutes. My email address is : naturaldubu@gmail.com

I thank you for your time.

Thanks

James Kim