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Hot!M96 Engine Project

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wibble
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wibble PCGB Member
2019/10/20 12:56:45 (permalink)

M96 Engine Project

For the past year or so I have been contemplating rebuilding an M96.1 engine as a side project to my 996 C4. I have been browsing a popular auction site for several months to find a more or less complete engine. To cut the story short I found a complete engine with intermix issues (see my post on same issue https://www.porscheclubgb.com/forum/tm.aspx?m=965335).
It was from an early 996 C2 Tip having done 133K miles. It was overpriced at the 'buy it now' but sat on it a few weeks until the price dropped then made an offer which was accepted.
Whilst many would think complete madness buying a broken engine, you only have to start looking at reconditioned engines and you'll realise the going rate is at least £5K plus in the current market.
 
So this post will follow the progress of engine strip down, maybe discover some horrors along the way and on to the rebuild with the help of specialists.
 

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Tony
1999 996 Carrera 4 - Ocean Blue
Past:
1990 944 Turbo - Guards Red

9 Replies Related Threads

    andywill
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    andywill PCGB Member
    Re: M96 Engine Project 2019/10/20 13:12:41 (permalink)
    Tony
    A very interesting project wish you all the best an please keep us updated.
    Regards Andy

    Andy Willis.
    996 Register Secretary.
    996@porscheclubgb.com
    Peter_Bull
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    Peter_Bull PCGB Honorary Member
    Re: M96 Engine Project 2019/10/21 15:22:25 (permalink)
    I will look forward to reading this thread and seeing the photos too!


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    wibble
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    Re: M96 Engine Project 2019/10/23 13:17:10 (permalink)
    Thanks Andy & Peter
     
    First task is to make room in my garage so I can get my car in, so the exhaust system (or scaffolding as I like to call it) needs to come off. Not the easiest tasks at the best of times as previous owner had made an attempt and given up.  I was fairly brutal with my angle grinder as the mufflers have seen better days with lots of corrosion around the seams. The exhaust straps were cut at the cat and mufflers removed using 3 bolts either side inside the hangers. The muffler hangers were removed relatively easily.
     
    So the cats have been removed and again an angle grinder and hacksaw were the only option to separate the 3 bolt flange cat to manifold. Literally the nut & bolt had rusted to a 'blob'.
     
    The manifold bolts look to be poor condition - notoriously difficult to remove without sheering. First bolt rounded off with an impact socket and heat applied! So I stepped back and have decided to remover cylinder heads complete with manifolds where I can assess the damage on a bench.
     
    post edited by wibble - 2019/10/23 13:20:13

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    Tony
    1999 996 Carrera 4 - Ocean Blue
    Past:
    1990 944 Turbo - Guards Red
    graham.webb
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    Re: M96 Engine Project 2019/10/24 14:04:11 (permalink)
    Great stuff Tony. Having successfully done one already, this should be a doddle....?
    Look forward to watching progress!

    Graham
    '91 944 S2: Alpine white
    wibble
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    wibble PCGB Member
    Re: M96 Engine Project 2019/11/11 13:27:17 (permalink)
    Progress made to earlier post. The top of the engine has been stripped back. This includes inlet manifolds, fuel line & injectors, starter motor, alternator, vacuum lines + AOS, knock sensors, oil fill and dipstick, oil level sensor, oil cooler and wiring loom. The water pump was removed and sheered one bolt. The oil pump to be removed and already one bolt sheered through corrosion. Despite all efforts to soak bolt heads in WD40, you just know that a bolt is about to break just by the feel. Not much can be done about it before it's too late.
     
    The pulse sensor on the bellhousing proved to be difficult to remove despite best efforts. Held in place by a single bolt it simply did not want to come out. In the end had to knock it out with a piece of wood from inside bellhousing dowsed in wd40/silicon spray. Whether this is common, but would not like to attempt this with engine in the car.
     
    From the photo you can see oil stains over bank I (similar on bank II reverse side). This is common as AOS becomes clogged up with residue oil- early tell tail signs that AOS is failing. The RMS looks good, not sure if its been replaced. The IMS housing looks original by the amount of rust. However, it looks like someone has attempted to check it as one bolt is new. I will have fun removing this component, no doubt.
    post edited by wibble - 2019/11/11 13:40:50

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    Tony
    1999 996 Carrera 4 - Ocean Blue
    Past:
    1990 944 Turbo - Guards Red
    wibble
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    wibble PCGB Member
    Re: M96 Engine Project 2019/11/11 13:37:58 (permalink)
    Latte anyone?  This the intermix oil removed from the engine.  The engine holds about 9ltr of oil. I have over 10ltrs here.  I had to remove the sump plug with a breaker bar and the filter housing I cannot remove at this point. Makes you wonder who maintained this engine in a previous life.
     
    Sorry for poor light in photo. It was Saturday 9th Nov, heavy rain all day and light was falling.

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    Tony
    1999 996 Carrera 4 - Ocean Blue
    Past:
    1990 944 Turbo - Guards Red
    carreraboy
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    Re: M96 Engine Project 2019/11/15 09:14:45 (permalink)
    Two sugars?

    Club Member since 1973
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    mahoneyj
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    mahoneyj PCGB Member
    Re: M96 Engine Project 2019/11/16 19:27:59 (permalink)
    wibble
    Latte anyone?  This the intermix oil removed from the engine.  The engine holds about 9ltr of oil. I have over 10ltrs here.  I had to remove the sump plug with a breaker bar and the filter housing I cannot remove at this point. Makes you wonder who maintained this engine in a previous life.
     
    Sorry for poor light in photo. It was Saturday 9th Nov, heavy rain all day and light was falling.



    Wow, what a state. Have you found the cause of the intermix yet Tony? 
     

    1994 968 Sport with a DAB radio... and now with Janspeed exhaust, ProMax chip and K&N air filter.
    There is a widespread and quite erroneous belief that cricket is just another game...
    wibble
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    wibble PCGB Member
    Re: M96 Engine Project 2019/11/18 10:09:22 (permalink)
    mahoneyj

    Wow, what a state. Have you found the cause of the intermix yet Tony? 
     


    Not yet. If I get time I will remove the cylinder heads before the new year. Usually the issue stems from bank I on cylinder 1. 

    Tony
    1999 996 Carrera 4 - Ocean Blue
    Past:
    1990 944 Turbo - Guards Red
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