atr911

Anyone here know if it's feasible for an amateur to rebuild a 996/997 motor? Are the tools available/needed?

Thinking about taking this on as a winter project. I have a 17 bay garage and 4 mechanics to lean on for help but none have ever rebuilt a porsche motor.

Quix

Atr,
Use the "search" function: A member called Logray has several well-documented posts about his rebuild saga. He includes lots of good pictures and commentary along the way. Also consider becoming a paying member as this community will be able to provide more help than you can imagine.

halik

I am jealous of that set up.

If i recall correctly, there were at least 1-2 people that have done the DIY rebuild.

atr911

Thanks for the heads up. I was a paying member for years. Let it lapse.

Ill check him out.

Macster

What others said.

But IIRC Jake Raby is rumored to be issuing a book soon on these engines and it might prove to be a worthwhile addition to the toolbox of anyone contemplating rebuilding one of these engines.

I do not know if there's anything on this book yet at his company's web site:

http://www.flat6innovations.com/

Sincerely,

Macster.

groovzilla

i'd listen to my daughters pet fish:

logray

It is possible. I did it, and there are others out there who have done it. The work I did documenting and posting here doesn't paint the full picture and is no where close to being a step by step guide.

I wouldn't even consider doing it as an ameteur unless you are very mechanically inclined, have prior engine experience, have tons of money and spare time, and are prepared for ultimate failure and waste of your money and time.

In fact, in retrospect, I would have been better off sending my car to Jake, for about another $8k on top of what I spent I could have had heads ported, a warranty, bearings and cams cryo'ed and coated, and the peace of mind knowing that it was done by the utmost expert on these engines. That being said, I have to say it was a really fun experience, I would do it again in a heartbeat given the time. I have 5 driver events and 6000 miles on the rebuilt engine... the only thing I've done since April is put air in the tires and change the oil once. Other than that, just get in, turn the key and enjoy the fun pedal, it has truly been a worry and trouble free experience once I completed the rebuild.

Honestly though, my story might be an exception to the rule and your best chance of success if you want to DIY is to attend one of Raby's seminars before diving in...

atr911

Shouldn't have any issues with the mechanical side. Never done a complete rebuild but I've swapped motors and done top end rebuilds and what not. Also, as mentioned, I have a 40 year VW/Audi tech, 47 year general mechanic and a 15 year Mercedes guy that I employ at my shop so there's no lack of knowledge among us.

My question was more in terms of tools required to do the job properly. I have the factory service manuals but they call for many special tools. Some I'm sure I can do without but others I may have to fab/purchase.

I'll look for some of your threads though, sounds interesting!

Apex996

>> Anyone here know if it's feasible for an amateur to rebuild a 996/997 motor?

I'm doing it. First flat 6 I've tried. Doing a 3.6L first and then a 3.4L. Whichever one isn't in pieces after I'm done goes back in the car

Go for it! Sounds like you have the resources.

jasper

A user named billyboy (local to me) is doing one as well. He broke a cam chain and has started a thread.

infrasilver

What are your reasons for the rebuild, just for the hell of it or do you have an issue?

I've just completed a rebuild on my 3.6 996 after I had a similar failure to billbob's with the cam chain snapping on bank 1-3, I was on track at the time it failed so consequently I got a lot more damage than billybobs.
It took me 3 months working at weekends to get it fixed and I managed to do it with limited space and mostly basic tools, I made one of my own and had the engine timing set at my local indie.
Some of you may already of seen this but this is the link to the thread over on the 911uk site if you haven't, http://911uk.com/viewtopic.php?t=74946







It sounds like you have the ideal place for a rebuild and its only an engine at the end of the day?

Imo000

Once you get a hang of it, they are not that difficult to figure out. One bolt at a time, and you'll get there.

Start the teardown and if you hit a snag, see what special tool you need to gk passed it. Then decide if you want to make or buy that tool.

Apex996

If you've built engines before this is not much different. Quite a bit simpler than what some on this forum might have you believe. After all, most 15 year old kids know how to rebuild Subaru boxer's don't they?

Infra... I'm building the first one to learn and the second one will be built for more POWER.

atr911

Yeah, it's funny how a little inexperience can get you though. Example: I pulled the cams without using the proper procedure. Ill have to get them inspected now. Shortly after, I turned the engine on the stand some of the hydraulic lifters fell out (they're supposed to go back in the same hole they came out of). GAH.

Tomorrow I think I'm going to split the case and see what kind of damage there REALLY is. I may be abandoning this if there's crank damage as they aren't easy to come by and oversized bearings aren't available.

Either way, this has been FUN

infrasilver

atr911, what is your engine failure? As you've already found out there is a lot to learn, but the best way to learn without mistakes is to read as much as possible before every step.

Porsche do stipulate that the lifters are noted from where they came for replacement but I had to buy 10 new ones so this made it impossible to put them all back in their original position.
You really need to take lots of pictures and label/bag everything even if its not going back in the engine because you are renewing, don't discard broken parts before you've finished the build, you may need them for reference. I nearly made the mistake of fitting a head before I'd fitted one of the crank cage bolts but because I did a mock up trial I realized I'd not fitted it, luckily doing this saved me a head gasket and 12 head bolts.
Another mistake I made was not tightening the crank case together quickly enough, allowing the Loctite sealant to go off before it was fully torqued, (bolts should be torqued within 5 minutes of fitting the sealant) I had to take the crank case apart and start again.

You WILL enjoy the build though, very satisfying doing it yourself, I will also add its not for everyone to just go ahead and rebuild, you will need some relevant experience, there are a few points along the way that'll trip you up if not careful.