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Just posted a docu. on my completed 02 996 M96 3.6 l engine rebuild for a gorgeous C4 cab barn find, I bough back in August 17 as roller with complete engine (Head&Case failure).
It is not about performance upgrades or how it should be done. Is about the process to get it done with very details on the critical steps for the hands-on engineer.
The car drives fantastic now, and if it breaks I will be confidently enough to spend the needed money and time to order on the new hard parts (Nickies, rods, heads, etc.... For now I did not spend anything other than on a high-mileage used 997.1 donor engine and a couple of 996 cases with paired pistons/rings from engines with other type of failures).
I wish I had an alike docu. when I started - so I share it here, and hopefully it is useful for someone who wants to bring a M96 996 3-chain engine back to life .
A friend and I have been struggling with a strange problem with his 2006 997 4S with tiptronic transmission.
When you start his car you need to turn the key and let it crank on the starter motor for around 10 seconds before it will start, and when it does it seems to be a bit lumpy for the first second or two.
However, if you shut it down while it is running and restart it right away it fires straight up within a second.
We have pulled off a coil pack and put a new plug into it (earthed out with a jump lead) and observed that while it is cranking there is no spark, apart from maybe one every 3 seconds, and then rapid sparking at the plug as soon as it fires up.
We have also hooked up fuel pressure monitoring kit to the car, and the fuel pressure seems to be right, as I thought it may be the fuel pump check valve or pressure regulator bleeding off pressure, but then we discovered what was happening with the spark not being there until 10 or so seconds of continuous cranking.
We have hooked the car up to the PIWIS and PIWIS-2 that the local Porsche approved bodyshop loaned to us, and there are no fault codes anywhere.
We also had hoped to watch the live data while cranking, but it seems that communication disconnects during starter motor cranking, which we are told is normal.
The strange thing is that the car idles fine, runs fine, no hesitation, we have followed the Porsche test plan for checking the mass airflow sensor, we have used a smoke machine on the intake to look for vacuum leaks, we have even checked the various temperature sensors on the PIWIS and all seem to be reporting good temperatures.
While we had the PIWIS-2 we even reprogrammed the DME with the latest software, which it said was already loaded but we did it anyway in case something was corrupted.
We have even disconnected the battery over night and tried the various re-training adapting methods on the internet.
Fuel trims are all hovering around 900 and 1.1
We have even changed the crank sensor for a new one and no difference.
If it were not for the loss of spark, I would be tempted to say it was the fuel pressure bleeding off, because it is a little like it is trying to get fuel back up to the injectors when cranking, which would also explain the way it only has this problem 5 mins after shutting the engine down, but not less than 5 mins.
Does the 997 DME monitor oil pressure before it supplies a spark? My reason for asking is that this would also be something which would match up with the symptoms, once the oil pressure has bled off completely, it would take a few cranks to regain it, especially if the oil circuit had a fault... But when running the oil pressure is good, however it does seem to be that the oil pressure is at the bottom on the instruments when cranking and either it shoots up and then the engine runs, or maybe it just shoots up due to the engine running at a faster speed than starter motor cranking.
We even worried it may be cranking a little slower than the DME was happy with, so even replaced the dreaded alternator/starter motor/charging harness on the engine.. Which now has it cranking a fraction faster, but still the same problem.
Having compared the cranking speed to my Boxster and 996, it seems to be turning over at the same kind of speed.
Any ideas anyone??
By Alexandre Charette
I'm doing the 996 to 997 GT3-RS front conversion and need to re-pin the headlight connector as the 997 use A5 Pin instead of A4 as the 996 (for the High Beam)
My question is how can I remove the pin from A4 and put it back in A5 ?
How to re-pin the headlight connector ?
I did a lot of search and didn't find anything specific on Porsche 996.
I've got a 1999 996 Carrera that hasn't had any mechanical issues outside of a water pump replacement earlier this year. Just today I noticed that when in 3rd to 5th gear (I haven't had it on freeways to see if it's in 6th too, but most likely it does) in the mid rpm ranges (2500 - 3000+) there is a vibration that I can feel through the gas pedal and throughout the car. When the gas is let up and/or when the vehicle is coasting the vibration goes away. The vibration seems to only occur on acceleration and does seem to be coming from the rear. The check engine light came on as well, at first it was flashing and is now constant.
Any tips on what this could be? Drive shaft? Engine mount? Catalytic converter? .....?
I live in Boca Raton, I have a 2005 997 - 911 with 93k miles. I'm not a rich man.
I'm looking for recommendations for service and repair in the south Florida area ideally someone who would like to work on a gentle restoration
or a recommendation for a reasonable shop that will do good work for a reasonable price i.e. not dealer rates.
I need a replacement alternator i think as the bearings have just gone (sounds like that anyway) and all the belts should be due by now.
Anyone with experience in maintaining this vehicle who wants to earn a little extra please contact me or if anyone has a show they would personally recommend I'd be very grateful.