red996

If the engine in my 997 ever fails I would be more inclinded to rebuild it myself than pay what like $10000 plus at a dealership for a new engine. This thread is inspiring. Thanks Imo000.

Imo000

There is a really good write up on Pelican on how take one of these engine completly apart. I'm only going as far as pulling the heads (short block).

Tomorrow evening going to Canadian Tire for the federal inspection. Called them today and sounds like they have little clue what to do. Should be a riot.

Cleaned up all the ports tonight. Have to lap the remaining 8 valves, clean up the mating surfaces and it will be ready for re installation. This weekend I'll be ordering all the new parts for the rest of the engine.

Imo000

Some small progress tonight. All but one valve are lapped in. Cleaned the deck surface with Permatex gasket remover, a plastic scraper and a razor blade held perpendicular to the mating surface. Tomorrow the valve cover surface will be cleaned and then the valves will be put back in.

Jaak Lepson

Boxster engine (2002S) is $18,000 + install, 996 would be more and 997 even more. Look at close to $20,000 plus to be out the door at any Porsche Dealer.

Indys will be bit less as they send it out to be rebuilt with latest updates (mine had LN IMS installed). Porsche take one from the factoy crate and installs it just like the one that came from the factory when the cars was built; no updates such as LN IMS.

The DareDevil

I'd send out the head and block halves to be resurfaced while it's all apart.

Imo000

The block is still together and won't be coming apart. There are no signs of pitting of the heads. The head gaskets looked normal. The first head cleanned up good. Might not look as clean as if it was re surfaced but having it machined down, for real reason is not my thing. If I have it skimmed now and in the future it needs it, there won't be enough material left to do it again.

Got all the valve wire wheeled. The heavy deposits on the exhaust valves came off really nice. Valve cover mating surface is clean now too. Need to really clean the head and then the valves can go back in.

tcc

As a real newb, I am following this this thread with equal parts horror, fascination and admiration. Fantastic chronicle of events and great pics! input from the community is fabulous too. So happy I found this resource. Going to follow this all the way to resurrection!

Imo000

I don't want people to think that this is any kind of a rebuild, it's not. It's a repair. I'm tying to get the engine running as good as it can without rebuilding it. It has 320 000km and I never heard it running. I'mnhoping with the replacement of the bent valves, new air oil seperator, new gakets and tensioner oads and thats about it. Will do a leakdown once its assambled and then back it goes.

Passanger head has all the cleaned valves is. The hydraulic lifter basket goes in tomorrow.

aviography

Might as well take this opportunity to change the transmission fluid now when everything is out in the open and easily accessible.

I was doing the fluid change tonight and had to take off half of the plastic shields under the car so I can swing the 1/2" drive breaker-bar to loosen the fill plug as it was very tight and won't budge with 3/8" drive ratchet, also couldn't even get my smaller electric impact wrench in there so had to manually break it loose with the 18" breaker bar, but couldn't get enough swing until the plastic shields are off......

The drain plug was pretty tight too, so I hit for 10 seconds with the heavy duty electric impact wrench then was able to crack it open with the 1/2" drive breaker bar.

Going to let it drain all night to get as much of the old, smelly, dark fluid out as possible.

tcc

Imre, you are a sick man!

Imo000

Not much to update. Been cleaning the other head. Got the intake valves lapped. Sunday all the parts for the heads have been ordered from Pelican, hopefully they'll be here for the weekend. Tomorrow evening the block will be next to clean. Half my time is spent cleaning all the parts.

jumper5836

So whats the plan you keeping it or repairing it to sell?

Imo000

Planning on keeping it.

jumper5836

With that many miles on it, I'd also look at replacing the valve guides.

Imo000

Not a bad idea but I had to draw the line somewhere so this repair project doesn't turn into a "while you at it" rebuild. I did check the guides when the valves were pulled and they felt "good n' tight".