3.6 engine tear down

[JFP in PA]

also...I see the headlight has a vent hose. the passenger side looks like is missing. I imagine there should be one?

20150808_202158.jpg

 

I think you are looking at the head light washer solvent line, and yes, both should have one.

[AWDGuy]

here?20150808_192726.jpg

That's where it goes.

thx.

that tube doesn't go to anything and I am looking at a diagram that shows it going to no where. are you implying this should be tied into the washer system somehow?

[JFP in PA]

 

 

here?20150808_192726.jpg

That's where it goes.

thx.

that tube doesn't go to anything and I am looking at a diagram that shows it going to no where. are you implying this should be tied into the washer system somehow?

 

 

Perhaps we are looking at different tubes, can you annotate your photo to indicate which one you are referring to?

[AWDGuy]

my apologies ahead of time if I'm not supposed to post this. #23 is what I think this is.

[AWDGuy]

the other side....missing

[Loren]

996 631 149 00 Ventilation component -- US MSRP $21.76 each

[AWDGuy]

Ok. ...so it is just a vent. perfect.

[AWDGuy]

took a video of some play in the IMSB that concerns me

https://youtu.be/CXNyadBk6SE

what do you guys think? should there be any play here?

[JFP in PA]

took a video of some play in the IMSB that concerns me

what do you guys think? should there be any play here?

 

Yes, there should be some play, and yours does not look all that unusual.

[AWDGuy]

good to hear. thanks.

[tac27]

ln was installed before I bought the car. I do not have the tools. I will probably use a shop in Montreal to rebuild it. one of the mechanics at this shop took jake rabys course.

I'm pretty sure the scoring was caused by the low oil pressure due to the clogged oil pick up.

I took that course last February.  Jake and Tony are great instructors, the professional techs taking the course were all very patient with us 'enthusiast, and the facility is really, really cool.

 

Jake mentioned something about getting a book out about rebuilding.  Hoping he gets it published soon.

[AWDGuy]

my wristpin/clip tool came in, thanks Bay Arean!

I opened up the piston box and don't see the clips. I guess I'll have to order those.

I have new main & rod bearings, should I get new thrust washers? those grooves face out, correct?

I'll order new oil scraper gaskets. part #'s are (if I did my homework right):

996-101-241-51-M100

996-101-241-51-M127

I pick up the bearing carrier case bolts today. what about the oil scrapers bolts? can I get away with reusing those? or should I order new in here also?

Edited September 22, 2015 by AWDGuy

[AWDGuy]

^ anyone? going to the dealership tonight to put in the order for the head, cases and valve cover bolts.

[Bay Arean]

Hey AWDGuy,

 

Any update? Glad your tool made it safely. Can't wait to hear if your installation goes as smoothly as mine did.

[AWDGuy]

No updates unfortunately.

you buy new bolts for everything or reused most?

[JFP in PA]

No updates unfortunately.

you buy new bolts for everything or reused most?

 

A lot of the fasteners are single use types and should not be reused.

[AWDGuy]

Bore is 3.9763

Were using the numbers in between the High performance strip & Moderate street use/turbo for our calculations.

Top ring
.0046 for a gap of 0.01829

2nd Ring
.0051 for a gap of 0.02028

oil ring will be gapped to 0.016.

Once filed down and gapped, I'll start performing the cylinder pulls with a fish scale to see what kind of resistance I get.  Jake gave me the numbers, so I'm hoping Im not too far off with my calculations, but I guess the pulls will tell us the story.

[AWDGuy]

was supposed to get to the ring install and perform the pulls last night but was busy with Jake and Tony's online course.

I'll hopefully get to it wednesday night.

[AWDGuy]

got the pulls done last night. we had the correct numbers on all cylinders, so I'm a happy guy. as I understand now, if we didn't have the right numbers, I'd be spending some time figuring out what rings to use.....so glad we got the numbers we got.

pretty consistent also across the cylinders. no more than 2 pounds difference.

we did 2-3 pulls for each cylinder just to make sure the numbers matched.

[AWDGuy]

heres a video of the pulls...

 

[AWDGuy]

And I got the bearings case and crankshaft done last night.  New coated main bearings from LNE, new thrust washers, ARP hardware.  Everything was cleaned and polished by a machine shop here in Ottawa.  They also did the balancing.











2nd most expensive set of bolts Ive ever bought



Main bearings pressed in. 





thrust washers installed, these have grooves in them and it is important they face out. One on each side:



added engine assembly lube to the bearings and washers, and dropping the crankshaft in:



Make sure those washers didn't budge as they just float in the groove





measure the thrust



Smooth as butter:

 

ARP hardware in and installed as per their recommendations.

 

Got the oil scraper on (no picture) with new gaskets and new bolts.  FYI - The bolts were changed by porsche from the ones they used in 2002.

 

Wrapped it all up in plastic and put it away, will hopefully pull it out next week to continue with the build.

Edited December 3, 2015 by AWDGuy

[Ahsai]

Nice video and pics. Any reason to use a digital scale as opposed to a mechanical one? The two close up crankshaft photos seem to show there's a groove on the crank journal, is that true? My '02 doesn't have that. Are the main bearings aftermarket? I see coating on them.

[AWDGuy]

I used what tools I had, that is really the only reason. I think that groove is just engine assembly lube from when we turned the crank in the half case...I'll take a closer look.

the bearings are from LNE, and yes, I believe they coat them. they are Porsche OE.

Edited December 4, 2015 by AWDGuy

[Ahsai]

Very nice!

[AWDGuy]

Charles at LNE offered me new rings they have for the 4.0 design. gapless rings. free of charge - how could I say no?!

big surprise was to get a new IMSB and IMS back from them. I sent in my old ones for an inspection, and Charles said they would exchange the IMS and send them back when the new rings come in.

everything is new!