David993S

After approx. 130K miles, my 996 engine started to develop a little piston slap noise. In addition to driving it on the street, I flog it around the track at DE's and track days. So I decided to do a winter engine rebuild. Here's what was done, and what parts were needed. I won't give costs because A) we all know it costs a small fortune, and B) the shop treats me really fairly and I know they cut me a break on labor.

WORK PERFORMED:
Remove rear bumper cover & tail lights.
Disconnect drive links and axles.
Drain fluids, remove engine & trans.
Separate units and perform leak test.
Remove exhaust & sub systems.
Remove cams covers and shafts.
Remove cylinder heads and drive chains.
Separate engine halves and inspect for damage.
Separate and clean all useable components.
Locate scored #6 cylinder.
Replace rod bearings & re-assemble original crank & carrier w/previously updated IMS.
Assemble case, install pistons.
Clean heads, disassemble, check guides, lap in valves, replace stem seals.
Install heads, replace chain guides, set timing, install sub systems.
Replace ignition coils and spark plugs.
Re-mate engine & trans, replace cooler control valve, replace motor mounts.
Reinstall engine, connect hoses & linkages, connect axles.
Add oil, bleed cooling system, charge battery, build oil pressure.
Run engine, prep to road test, set pressures & system readiness.

PARTS USED:
8 flywheel bolts
1 coolant hose
1 shift cable end
1 coolant hose/transfer
1 coolant hose/supply
1 engine gasket set
24 cylinder head bolts
1 chain guide rail
rod bearing set (12)
connecting rod bolts (12)
2 sealing compound/drei-bond
1 engine case (good used) *
6 pistons w/rings (mated to case) *
2 gal. coolant
10 qts. motor oil (Mobil 1)
oil filter/housing
6 bol & locknut exhaust
1 Oil pressure sender
fluid, power steering
6 washer
6 spark plugs
6 ignition coil (updated)
1 oil cooler
1 connector pipe, coolant (stainless)
1 flow valve, trans cooler
2 engine mount
2 O-Ring/PS line
14 Hose clamp/Serpentine Belt

* to economize, shop had on hand a good used (40K miles) case w/pistons.
Lifters previously replaced.

Kind of a long list, but that's what it takes to do a rebuild on a 996 engine, plus a few other odds/ends. Hope it is helpful to someone.
Cheers.

dporto

808Bill

More helpful to have the costs involved...I bet it feels good knowing you've got a fresh motor!

Imo000

Did you do all the disassembly and assembly of the engine?

David993S

No, the shop did all the work.

Imo000

Don't see the main bearings on the list.