Carlvs

On the seat rails.

 

With the throttle  cable disconnected squeeze together the top and bottom of the rectangular black bushing and push it  towards the front of the car.

A link to my parts used and prices for the 99 996 engine rebuild. Still running after 5,000 miles. Fingers crossed every time I go out 🙂

https://www.ez-bizwebs.com/3.4/images/Spreadsheet/Porsche996_EngineRebuild2.pdf

 

Unfortunately JFP in PA  is correct, at the minimum cylinder head, rod and main bearing bolts. I would also replace timing chains the timing chain rails and possibly the tensioner depending on mileage. Good time to deal with the IMS bearing and water pump. @ $299.00 Raby’s manual will save you many hours of grief and possibly thousand of dollars and lots of heart a he.

About a year ago I rebuilt the engine in my 996 and information was extremely difficult to come by. Lots of books will show you how to remove the cylinder heads but it stops there. I was able to piece things together by watching YouTube videos and a copy of the factory manual that I found on the Internet. Jake Ruby of Flat Six Innovations has a CD available that is supposed to be excellent.

 

Good luck.

Well I went through something similar. Bought a 99;Cab with a coolant oil intermix issue. Rebuilt the engine and had the heads repaired. Cracked Rh cylinder head.
Your cheapest option is to find a used motor and have someone install it. Lots of unknowns going that way.

Have a shop pull the engine and just do the cylinder head repairs. 
Pull the engine and replace with a short block and repair the heads.

If you’re not attached to the car, Sell it as a roller and move on.

 

How many miles on the car and what condition is it in? Get some estimates on the various options and you’ll have a better idea on how to proceed.

 

Best of luck!

Great!

 

Picture of bushing.



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I also discovered that removing this plate, the alternator mount and coolant blocking plate, ,

 

Makes life easier, and prevents the unfortunate crack seen above.

 

 

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Hi, my experience is that the alternator installation and removal are quite easy once the small fragile hose connection is removed. Hose to Oil Separator - 99610622652, yes you loose little coolant but it is no longer a struggle.

Great time to replace it with a new one ore better yet an aftermarket ally piece.

 

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I rebuilt my 3.4 engine for the same reason,  cracked cylinder head. Also sent to Hoffman’s. Great work, still running strong with about 3,000 miles since rebuilt. Yes the baffle is only on one side. May have something to do with the direction of the chain movement.

Morning all,   Short history. 2004 C4S Cab.  I bought the car one year ago from a Porsche dealer.  One month later I smelled antifreeze inside the cab with the heat on.   Another Porsche dealer garage pressurized the system for an hour showing no leaks.  The odor is still present.  I took it to a private Porsche specialist.  After three weeks,

pressurizing the system, changing the coolant, changing the oil and boro-scoping the cylinders, he found no leaks.  The odor is still present and getting stronger.  

I found yesterday my oil was one quart low.  I added a quart and found this.  See the photo.  I think I now have coolant mixing with oil.  I'm afraid to drive it but want other 

opinions before I start scheduling a mechanic to look at it or go back to the dealer where I bought it.   Thank you. 

 

I had a coolant intermix on a 99 Cab that I purchased used last year. The oil under pressure was leaking from a cracked in the cylinder head into the coolant. The coolant had turned into a murky tan/brown sludge.

What I see on your fillet cap may just be condensation mixed with oil... hopefully.

 

It’s possible that you have a small leak in your heater core.

 

 

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I posted my rebuild on Rennlist at 

 

 

There seems to be a many more posters there along with feedback. Have you tried that site?

I did mark the scavenge pumps prior to removal. Be sure to replace the guide rail plastic sliders for the cam chain and Vario tensioners.

 

 

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When I rebuilt my motor last year to have a crack on bank two repaired I do not recall turning the motor over again. It’s a different story altogether when you go back and reassemble everything. I sent my cylinder heads to Hoffman at Hammer Heads in Georgia and was very pleased with the quality of work that he did.


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I had a similar problem on my 99 996. I sent both heads to 

 

 

and was extremely satisfied with the results. I now  have over two thousand miles on the rebuild and all is well.

Yes, I’d recommend the Durametric Scan tool. 
 

 

Try this link..

 

Throttle cable adjustment - Rennlist - Porsche Discussion Forums

RENNLIST.COM

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996 Forum - Throttle cable adjustment - Anyone ever have throttle cable break on their C-2, mines not broken but throttle plate seems to stay open slightly causing a high idle. If I manipulate the gas pedal the idle will go down to correct rpms. Not sure if the cable is sticking or if its in the throttle body...  

Hi Nordiques,

 

there is an orientation to the square plastic grommet at the throttle body. If not correct it may be your problem.

 

good luck,

 

In recently rebuilt my 99 996 engine for the same reason, cracked cylinder head and an intermix problem. Make sure that you have some free play on the throttle cable and I would either replace the oil pressure sending unit or check your oil pressure with a mechanical gauge. I’m currently using a 5W 40 oil and getting about 1.5 bar at idle when warmed up and between 3-4.5 bar depending on RPM elsewhere. 4-5 bar at idle when cold.

 

 

 

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The part you need is available used at dc Auto. For $20.00 plus shipping.

 

 

I hope that it does not worsen! But... if you should need new cases I have good set on Rennlist in the classifieds.

 

 

Hi Cody, how many miles on the Boxster and how cheap? My suspicion is that it has a failing IMS bearing. If you’re not familiar with the term, google it and you’ll get quite the education on Porsche engine problems and potential cost in the thousands! If it’s cheap enough and the condition warrants, it may be worthwhile to peruse. Let’s see what other forum members have to say. Good luck.

Nice fuse diagram here.

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I would ask for a recent oil analysis.

Okay, By any chance do you know an alternative way that I could get a new ignition switch, rather than going to the Porsche dealers?

Look up the part number on a Porsche dealer site and then google it. Lots of vendors out there with OEM replacement parts/switches etc.


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