3.6 engine tear down

[AWDGuy]

got more done this weekend. wish i had more time, I would had the cases apart if so.

so far, following the guides Ahsai put up and the pelican parts Web page has proven to work well so far.

[AWDGuy]

flipped her upside down

found this in the pick up tube...looks like gasket maker, and what would look like beer bottle glass???? wth? no metal chunks though.

[AWDGuy]

Hoping by the end of this week, the cases are split & I can send off for cleaning before shipping out to LN Engineering.

[questforbalance]

Man, AWDGuy, that is some undertaking!!! What will you do with the scored cylinders? How will you fix them?

[AWDGuy]

I'll leave all that to LN Engineering. looking at this right now:

http://lnengineering.com/products/watercooled-cylinders-pistons/porsche-boxster-cayman-and-911-model-years-1997-2008/36-911-nickies-inc-96mm-fsr-je-piston-set-inc-rings-pins-clips.html

may go from a 3.6 to 4.0. still doing some homework. it's the same price, so why not.

Edited March 9, 2015 by AWDGuy

[Ahsai]

Nice photos! Just wondering if you had low oil pressure reading before the failure? The oil pick up seems to be clogged by ~40%.

Wonder if those are worn chain rail material clogging the oil pick up, which leads to oil starvation then cylinder scoring.

[Ahsai]

I'll leave all that to LN Engineering. looking at this right now:

http://lnengineering.com/products/watercooled-cylinders-pistons/porsche-boxster-cayman-and-911-model-years-1997-2008/36-911-nickies-inc-96mm-fsr-je-piston-set-inc-rings-pins-clips.html

may go from a 3.6 to 4.0. still doing some homework. it's the same price, so why not.

Good choice...good choice..I'm drooling now :)

[AWDGuy]

Nice photos! Just wondering if you had low oil pressure reading before the failure? The oil pick up seems to be clogged by ~40%.

Wonder if those are worn chain rail material clogging the oil pick up, which leads to oil starvation then cylinder scoring.

I don't remember to be honest. chain rail heh.....I'll take a look at that tonight.

[AWDGuy]

Yeah. ..that material is chain rail material.

more pics! got the cases split. is there supposed to be any play in the IMS bearing?

[AWDGuy]

off to get cleaned, then off to LNE. :)

[PTEC]

Cool thread, sucks it had to happen though.  Glad to see someone not scared of tearing one of these engines apart.  Do you have the tools for reinstalling the wrist pin and pin circlips for cyls 4-6 when you're reassembling?  Also just out of curiousity did you have an IMS failure or did you install the LN preemptively?

[AWDGuy]

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.

Edited March 21, 2015 by AWDGuy

[AWDGuy]

got to taking apart the carrier and pistons. took 20 minutes.

and more pics for bolt/sensor documentation. ..

[Ahsai]

Keep the photos coming! How many miles on the engine and was it rebuilt before? The main bearings look pretty worn out.

The thrust bearing On the left seems to be facing the wrong direction. Was it flipped before the photo was taken?

[AWDGuy]

106 000 km on this motor. don't believe it was ever rebuild. those two fell out as I was pulling the carrier off...just put them like that for pics.

[b-man]

got to taking apart the carrier and pistons. took 20 minutes.

and more pics for bolt/sensor documentation. ..

 

 

Thank you very much for the pictures and updates.  I am looking forward to your future posts.

 

b-man

[AWDGuy]

anyone have specs for the crankshaft? specifically the measurement for the bearing journals? the machine shop said they can look at all that for me as long as I provide specs.

Edited March 25, 2015 by AWDGuy

[b-man]

anyone have specs for the crankshaft? specifically the measurement for the bearing journals? the machine shop said they can look at all that for me as long as I provide specs.

 

I heard that information was never published by Porsche.

 

b-man

[AWDGuy]

****teh, they don't look bad so maybe a light polish will do

[JFP in PA]

****teh, they don't look bad so maybe a light polish will do

 

It will have to, there are no undersized bearings for these engines.

[Ahsai]

I stumbled on these while surfing http://europeanpartssolution.com/products/over-sized-bearings/

Seems to be something new and I wonder if anyone has tried these.

 

[Edit] Looks like they are available only for MkI engines though.

Edited March 25, 2015 by Ahsai

[Dharn55]

Nice that someone is finally making oversized bearings for these engines. But $999 for a set of bearings is pretty crazy. Better than the cost of a new crank though.

[JFP in PA]

The company selling them, under their "EuorpeanParts" name, is the same company pushing the roller bearing IMS replacement, which has already drawn some heat elsewhere.

[AWDGuy]

lne is supplying the bearings. I'm sure the crankshaft is ok. bearings are worn but nothing looks scored or cooked.

I should know more next week. machine shop is done cleaning the cases so they are off to lne tomorrow.

[Ahsai]

So the chain of events is

Worn timing chain guide shedding bits -> the bits clogged the oil pickup -> low oil pressure -> massive oil consumption + toasted bearings + scored cylinders?

Did you notice the low oil pressure when the engine was still running?