I do not know if I shared this with any of you guys yet, but for the past year I have been rebuilding my wife's 2004 Cayenne S motor (4.5 V8).

I finished it recently, and wanted to share my story. Full story is here on page 10:

https://rennlist.com/forums/porsche-...cement-10.html

End of the story:

Well,

I have to say a major thank you to everyone who helped me along the way, and a huge shout-out to Jake Raby @ Flat6. A lot of people contacted me through my journey asking me for my advice, and I told them to go see you Jake! Hopefully I returned some of the favor...

Without further Adieu, the story of the beginning of the end:

January 4th 2014 was the day it broke down, and I optimistically told her "I'll have that running in a month." Well, I had the engine out and torn down in a month. But little did I know there was a long grueling research process to determine what exactly I was going to do.
Christmas was coming and I was very nervous that I would not have my poor wife's Cayenne finished for an entire year.

I hustled and got it done though! It came to life on the first crank (that is after I cranked it a fair few times to build oil pressure w/o fuel pump fuses). I ran it for about 20-25 minutes and then changed the oil filter and topped up with break-in oil. (Brad Penn SAE 30). I was so excited I can't even explain it...

Anyways, enough with the talk, here are some pictures! Who says there is a limit to what you can do in your drive-way?!

Here it goes:





In!



And this is how you torque the crank pulley bolt...



Before and after flex pipe fix! Thank you exhaust shop... saved me $$$$$$! Those new pipes were only 60 bucks ea. then a couple hours labour to install. Beats 1500 price from Porsche.





Finished all the other work ahead of time so all that was left was exhaust. I know the shop owners and they let me finish her off in house



Looking good!



And again



So I finished my break in oil run and changed out to regular 0W40 synthetic, and ... that's it! I was back to fixing regular problems which I was so longing for... I finally spent the time to do the headlight harness fix on the one side - turn signal wasn't working because of it.

I can't explain how relieved I am to have this project finished and the car back on the road.

We took it to my Aunt's in Mississauga for Christmas dinner, and my wife was thrilled to finally have our family SUV back on the road!

Here we are on Christmas day!



And a youtube video of startup (after oil filter change, to prove it does actually run hehe):



Thank you again for all the help everyone. I was happy to contribute to the thread, although I wasn't able to document in as much detail as I would have liked. Having a pregnant wife and then newborn throughout the process made it very difficult, so be happy I posted what I did! lol

Cheers, and warmest regards

Jonathon

 

Those transmission bolts looked like a bear to get to

Great job

 

AMAZING!

Congrats on such an accomplishment Jonathon. Kudos.

 

big project, good on ya!
what did you end up doing for cylinder sleeves and pistons?
Cheers,
Rob

 

There were many parts of this project that were not fun! Lol

 

Moar of the wife!

 

Thanks for the kind words guys. Rob I had the block nikasil plated by millennium technologies and put in wiseco racing pistons

 

Wow, impressive job!

 

Well done! Thanks for documenting it too.

 

Looks great! Good work! ....so shiny!

 

Now THAT is a breaker bar!

 

Actually believe it or not Christien, that's a 3/4 drive torque wrench, same one we use to torque the wheels on the Cup Cars

 

And of course my home-made crank pulley tool for the cayenne. If anyone ever needs it let me know (I hope you don't, for your sake...)

 

great work. Amazing with a pregnant wife and newborn. Most wouldnt have even bothered to attempt the work at that point.

ps: your first name is misspelled

 

Just clarifying here, perhaps my wording was bad...

Pregnant wife which then turned into a newborn and no longer pregnant wife. lol