Flat6 Innovations

Eddie,
Yes this baby is strong. I can't wait till we make the updates and re-dyno the car. It probably won't make must more peak power, but the changeover will be more linear and the graphs not as bumpy..

Its a nice car, reminds me a lot of my '99 C2 Aero that my Wife set her Land Speed Records with.. I wish I hadn't sold it!

Flat6 Innovations

Today's progress... Began working with the vario-cam related items and inspecting the heads for cracks.

Note the wear on the vario-cam wear pads.. This is totally normal at any mileage over 40K and is the cause of that bumpy torque curve and the radical plot changes at variocam changeover @ 5,200 RPM

Flat6 Innovations

Here we are finishing disassembly of the valve train, looking for cracks forming in the heads under the lifter carrier and measuring the lifter carrier for wear. Worn lifter carriers lead to lifter failures, so we use a telescoping gauge and a small bore gauge to measure for this. Simply "changing" lifters without these precautions being taken leads to failures. We have had to create our own specifications for this wear, because none are posted by Porsche.

By the end of the day we'll have the IMS bearing pulled.. Just took a lunch break and decided to post some pics.

Now on to upgrading the oil pump drive key, chain rails and other vario cam based components..

fasteddie99

"Peace of mind" is flooding over me...

Flat6 Innovations

Some more progress. Ended the day at a good stopping place.

- Some upgraded FSI lifters.
-A worn Upgraded
-I upgraded Ed's cam drive sprockets from the early two piece (problematic unit on the right) units to the later revised units that are single piece
-Pic of the early and late cam drive sprockets
-Shot of the crack-free 4-6 cylinder head

Flat6 Innovations

Its been a crazy few days around here.. I haven't had the necessary time in the Office to update the progress with Ed's 996, so i apologize. The good news is the car is good to go and has passed all my tests with ease, we just need to replace his B&M shifter arrangement that was broken previously and do one final dyno run, then hunt down a squeak in the suspension for him.

Here are some more pics of what we've been up to:

Crankshaft locked at TDC for reinstallation of camshafts and camshaft timing procedures


Camshaft Timing Procedures being carried out


Installation of revised camshaft drive sprocket


Close up of new vario cam wear pads and 4th/ 5th drive chains


Comparison of OEM oil pump drive key and the update billet drive key. I've lost an engine to this, so we ALWAYS update them!


Installation of the new billet drive key


Machining the case for the under drive crankshaft pulley.


Shot of the nasty OEM IMS flange


Flange pulled to see the dual row IMS bearing


Extraction of the OEM IMS bearing using the Flat 6 "Pro" level extraction tool.


Bearing extracted.. Here is the release of oil that proves the bearing was at stage II of the four stage wear sequence. The inner and outer seals were compromised


Ed's Dual Row IMS bearing


Cleaning the seal debris and nasty oil from the IMS tube


Insertion of the new bearing with our worn out driver! Thats the first driver that was made, its well used! (big hammer for added effect!)


Dual row ceramic composite hybrid retrofit bearing inserted and ready for the lock ring to be installed


Installing the lock ring


Billet IMS drive flange installed and torqued. Flange was then serialized to quantify that Flat 6 did this retrofit. The flange number matches our logbooks and the retrofit sticker in the door jamb


Pulling the RMS


Installing the new RMS


RMS installation complete


Engine and transaxle married, ready for integration back into the vehicle


Up and in!


Ready to add the rear bumper and go from there!


Ed's mileage total.. The trip odometer reads the mileage that I test drove the vehicle prior to "blessing" it to go home to Ed. Thats a test drive, but we have to do this with cars being shipped cross country for our work.


The "NO BS" decal that proves the job was done right, by the people who perfected the procedure. This is Retrofit #202 for the Flat 6 Team, more than anyone else!


Ed wanted enough of our Flat 6 Oil for two oil services, so we dispensed 5 gallons of the secret sauce and will be shipping it home in the trunk of the car for him :-)


This one is done, one more dyno run and she is outta here!!

Ed was great to work with, like all of our clients. Thanks for the opportunity to serve you, Ed

fasteddie99

What are those hexagonal-shaped pieces, Jake?

Flat6 Innovations

Ed, I added captions to the photos... They explain the hex drives :-)

fasteddie99

Thanks for everything, Jake. Wish I could shake your hand!

Optical TDI

Very thorough. I'm guessing all of this work is not part of the $3,500 service?

fasteddie99

Correct. I got the engine upgrade package as well.

chsu74

Nice! Jake was able to fit you in with a 3-4 week turn time. You are one lucky man.

Flat6 Innovations

Yes, he was lucky.. Only because all the planets aligned and we have 3 engine builds on hold due to a slow down with the Nikisil cylinder plating process.

We have an empty truck on the way back from california with space open if anyone is interested.. Ed's car will be heading back on that truck.

fasteddie99

Funny, my wife says that often...

Flat6 Innovations

Ed is lucky to have his 996!! The car drives and handles awesome, I had fun putting the test drive miles on it :-)