DBJoe996

I think you are going to have to experiment with sealants.  Has to both be oil resistant and handle the exhaust temperatures.  I think the idea of a stud is a good one to try.  Maybe a stud and some sealant on the threads like this would work: 

It helps if you give the year and model of your car.  Anyway, my 99 C2 dash lights do not come on unless I turn on the headlights.  So I'm wondering if maybe the light switch is bad.  Have you tried turning on and off the headlights?

15 hours ago, mdreef said:

One additional thought for my CEL is that I noticed the clip that connects the upper AOS tube (#5 in the diagram) to the AOS is broken. This means that the o-ring is likely not making a positive seal.  Could this be the cause of a vacuum leak that would affect the SAI system?

 

 

Yes, that could cause a vacuum leak.  Probably not an issue/problem for secondary air injection.  SAI pump runs and pumps air (positive pressure) into the exhaust system to light off the cats.

In my opinion, the secondary air injection system is a bandaid to USA emissions control and should be entirely eliminated.  You should consider the cheaper alternative of having the ECU/DME programmed for ROW (rest of world) coding to eliminate/ignore the SAI system.  Try the ECU Doctors...they can do it.

Specialized ECU Repair, Replacement Testing of Electronic Control Unit

WWW.ECUDOCTORS.COM

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Porsche, BMW, Ferrari - We'll make any used ECU work - Send us your damaged ECU and we'll TEST and REPAIR your unit and send it back to you with our 5 YEAR WARRANTY.

#7 and #8 here

I'm not really sure what you are asking.  The part number is for this: 

Try to reset the window limits.  Push the button to close and when it has reached the limit continue to hold the up button for 10 seconds.  Do the same for down, push down and hold the button for 10 seconds after it is down.

When you replaced the AOS, did you remove the TB and left intake?  There may be some residual oil in the intake.  The AOS vents to Bank 2, the right side of the engine and left exhaust pipe.  Having a bunch of oil in Bank 1, and right exhaust pipe, does not sound good.  Thinking on it....

I have heard of cases where a faulty MAF sensor causes the ABS/PSM to malfunction.  Sounds like you headed in the right direction with fixing the wiring to the MAF sensor, and replacing it as well.  Do you have Durametric or a scanner to check for codes?

1 hour ago, Stringy said:

I too had a very difficult time in getting my alternator out.

I must have hit it hundreds of times but the steel insert didn't seem to move - I even resorted to drastic action, see pic.

 

I didn't read the message above that said it only has to be moved so it can be rotated up and out.

Anyway, eventually I found I could pry the alternator up free of the bushing.

At one point when I was prying, I pushed the alternator up and causes a short hiss - sounded like air?

No water dripping, so time will tell if I've damaged anything.

Once out, I tested the windings and diodes and concluded the regulator - which is was. $18 from the bay.

p.s. I also checked for poor connection of the battery leads - I used a PAT tester (Portable appliance tester), which has a 25A earth continuity function (at low test voltage), this showed a fraction of an ohm on all battery + and ground connections.

Hope this helps.

Better check the AOS coolant hose just to the right of the oil filler tube.  That plastic hose connector always breaks. With the engine off not much coolant will  leak.  With the engine running it will look like a geyser spraying coolant everywhere.

No, the engine wiring harness is a whole unit that connects to the X51 connectors in the engine bay.  It would be extremely difficult to replace just the cylinder 3 wires in the wiring harness.  Maybe you can find where the wire got pinched, and repair just that wire.  Agree, it's going to be difficult in that location but it has to be done.  What if you were to lower the engine to the frame and see if you can reach it?  You had to do that to replace the AOS.

What version is your DME?  Error codes differ for version 5.2.2, 7.2 and 7.8, and since your car is a 2000, it could be 5.2.2 or 7.2

I would say generally that they (injectors) don't go bad, but just get clogged up.  They  can be rebuilt by a professional/specialist.

Yes, that is the correct Workshop Manual section.  Maybe someone with experience will weigh in on the pressure testing tool.  I don't believe there is anything unique about the pressure testing port (schrader valve on the fuel rail), maybe a local auto supply stores might have one that will work. What you want to see is if the fuel  rail stays pressurized with engine off, or if it bleeds down, meaning the fuel injector for #3 is stuck open as JFP pointed out.

Sure would get old fast.  I'm in Florida and cannot live without AC.  What is the dreaded "black box"?  From what you described it seems all the AC system components are okay, thus recommending having an AC specialist give it an all out refresh of the refrigerant.  Sounds like you might be low.  Most of the time the "recharge" cans from the auto 

store just don't work to push more refrigerant in the system.

It sounds like all the major stuff is working.  At this point I would take it to an AC shop with the proper equipment to vacuum all refrigerant, flush the system with nitrogen,  and recharge the system with the proper amount and type of refrigerant and oil. Question - when you turn the AC on do both of your radiator fans turn on low?

What year and make is your car? There is a guy over on Rennlist selling a bunch of parts from a 2003 C2.  He might have an immobilizer.

Here is a picture of my door sticker

Agree totally with JFP.  Coil  packs and plugs are where to start.  Check them out.  Also, not having driven in over a month means perhaps your tank of gas is old.  Might not be the problem but adding some Techron to the tank, and a full fresh tank of gas wouldn't hurt.  Plan on changing the oil after that tank has run through.

In 2000, Porsche C4 production (for coupe) was 3,862

Source -

Porsche 911 996 Production numbers by year and version

HOWTOPORSCHE.COM

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Porsche 911 996 productioni numbers for all versions by year. Model No. built 1997 Carrera Coupé:14 1998 Carrera Coupé : 8296 1998 Carrera Cabriolet : 952

Your engine number is M96/04  66Y 14721

One thing that would be helpful is a picture of the door frame sticker that shows the actual date of production.  For instance, my car was sold as a 1999 C2 coupe, but was made 7/98. Maybe you can get that during the PPI

Here is my 99 Model Year M96/01 engine number.  Per the above chart, a 2000 should have an engine number M96/0466Y....

I don't understand that engine number.  Here are examples of engine numbers:

5 hours ago, Don Smethers said:

Thank you for your replies. Agreed, on this specifiec car, if there are no records of an engine replacement or an IMS upgrade, then the safe assumption for a 2000 is that the small single row bearing is in the engine. Of course, since the factory didn't know of the failure rate until later, there may not be an engine-by-engine record kept or being accessible at this time. Does this sound right? So, I'm still shopping for my next Porsche.

Look for a 98/99 996 from Southern California. Dual row IMSB, stout and robust, no rust.  And like JFP said, give us an engine number and we will dissect it to the nth degree 🙂  I have a 99 manufactured in 7/98 with 145K + miles.  I do regular oil/filter changes twice a year and I do not worry about my IMSB at all.  I got an LN spin on oil filter adapter and magnetic plug.  Never anything on those to give me problems or reason for concern.

As said, for a 2000 it probably is a dual row IMSB.  But if the engine serial number has an AT in it, then the original motor has been replaced and you cannot know what type of IMSB is in it.  Only physical inspection will reveal what is there.  The good news is if the IMSB is dual row or single row, then it can be replaced with the LN Engineering IMSB Solution and you are done with the issue forever.  However, if it is a AT replacement engine with the larger IMSB (later replacement engine years) that can only be replaced by disassembling the engine and splitting the engine casings. But, also, the larger IMSB is not problematic with proper oil changes and change intervals.

ECU Doctors can help if the immobilizer needs waking up.  For in the future, they have a waterproof box for the immobilizer.  Since the immobilizer sits in a well under the seat, it is most prone to getting wet.  If the seat is not responding to fore and aft movements to loosen the floor bolts, let me know.  There is another  way to get under the drivers seat. 

Porsche 996 (1999)

WWW.ECUDOCTORS.COM

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Porsche, BMW, Ferrari - We'll make any used ECU work - Send us your damaged ECU and we'll TEST and REPAIR your unit and send it back to you with our 5 YEAR WARRANTY.

If the carpet behind the drivers seat is wet, then surely the carpet UNDER the drivers seat is wet, and that is where the immobilizer/alarm system is.  If you can, remove the drivers seat (loosen floor bolts and tip it backwards) and get the immoblizer unit out.  Dry it and place it in a canister of dry rice for several days.  Remove the carpeting and  get it dry.  If you can, put a dehumdifier in the car and get it completely dry inside.  Shop vac out moisture from the carpeting.