guthrie

Loren, Thank you, I looked over the pics and began to read the article. Do you know if there are special tools that are need to split the crank case and deal with pulling the pistons? Additionally, any special tools to put it back together again? Is this a DIY adventure? Thanks Hi I did the rebuilding of a 3.4 engine by myself. I have no previous experience on those things, but had the Porsche workshopmanual. Without it it would have been impossible to do it. The only "special" tool required was a home made piston circlip installation tool, which I made from two plastic tubes. See attached picture. I cannot remembre the diameters of the tubes, but I think the bigger one was about 3/4", and the inside one was just able to slide inside. I had to sand away a bit for the exterior tube for it to enter the piston installation hole. I looked the exact position of the circlip, and made a blue line into the "installation tool" to be able to line it correctly to the piston. The small cut you can see in the exterior tube is where the circlip´s hook has to be placed. It was a bit problematic to put the circlip inside, but I found out that even it was not completely perpendicular to the tube, it went into it´s place without problems. Just a light hit to the inner tube, and the circlip went into. Just press the exterior tube tightly against the piston. I was surprised how easy it was,in the end, after months of investigation how in heaven I´m going to get the circlips in.... When I opened the engine, I removed the cams together with the variocam unit, so here was no need to adjust them. The chains were OK. I also made a small thing to hold the cams inplace when the valve cover was removed. Otherwise there were no big issues... Saludos Kare Smartrepair... Thanks for the insight. I see the picture of your tool, the pipe in a pipe however can you explain a little more, how exactly do you use it? Can you define the "circlip"? And finally where does one acquire a "shopmanual"?

Loren, Thank you, I looked over the pics and began to read the article. Do you know if there are special tools that are need to split the crank case and deal with pulling the pistons? Additionally, any special tools to put it back together again? Is this a DIY adventure? Thanks

Are the 3.4 and 3.6L watercooled motors designed to be rebuilt or simply replaced if a cylinder is "dead"? I performed a compression test on my motor and 5 cylinders delivered about 250psi and the last cylinder averaged 40psi!!! I repeated the test with the same results. The bad cylinder is number 4. I would like to take the motor out and tear it down and rebuild it with new rings. I am targeting rings because the leak down test didn't show any problem with the valves but did show problems with the rings. Additionally I am getting tremendous amounts of oily smoke out of the air oil separator, exiting out of the hose that returns vapors back to the intake manifold. The hose resembles an old locomotive chugging away.

Loren, It's not stock b/c we converted it to a one way catch can rig. Using the port that I believe would be used to vent the air back into the intake manifold, we diverted that hose to a catch can mounted to the fire wall. After reading about failed AOS that push large volumes of oil into the manifold I believe I have a worn out AOS. I say that b/c after about 30 minutes of running my 1 1/2 quart catch can fills up! So I was going to replace the main AOS unit. But to make sure I didn't mess up, I wanted to change the system back to stock. Also, there are two hose ports on the top of the '05 AOS that look as if they are vacuum line hoses??? if they are I am wondering if they need to be put back on. If you can help I would appreciate some advice. If the link below works it is the PET diagram of the 996 AOS. Look at the top three hoses, these are the one in question. http://dcauto.gotdns.com/index.php?mode=pa...amp;illo=104-10

When looking at the '05 air oil separator there are three hoses/pipes coming off of the top end of the AOS. Does anyone know where these three lines go? If you are looking at the PET diagram the hoses I am interested in are numbered 12, 5, and 13. Mine is not "stock", I am attempting to change it back to stock and don't know where to route these lines. Any help or diagrams would be greatly appreciated. Thanks guthrie