997.1 Carrera S (bore scored)

[Katanator]

Latest addition to the garage. 2005 997 S tiptronic.

Will add some more pics later.

Car is in immaculate condition, 78000km with a little twist.

It presented with the dreaded bore scoring tick, cylinder 6 misfire, and wetness around exhaust manifold gasket.

After bore scope scoring is confirmed. Spark plug tip completely burnt away.

This was known beforehand so car is taken on as a rebuild and sleeve project.

Most prices and component list already determined, still busy deciding on best engineering shop locally for ductile iron sleeves or alternatively also got pricing and shipping from Hartech for a Nikasil sleeve.

Open to any or all advice and will share the journey.

 

[Katanator]

 

[evnmopwr]

Common issue with these.
RS Autosport comes to mind. They maintained all my cousins Porche's
Maybe they can advise who best to Do that engine?

 

[Peter@AEW]

A lovely project
I am not so sure on the sleeving part as engineering will need to be very accurate so that the sleeve does not shift as it goes into heating cycles.

First prize is a new block obviously.

Looking forward to the build.

 

[TBP88]

I'll go devils advocate and say it...

LS swap candidate...

 

[Katanator]

A lovely project
I am not so sure on the sleeving part as engineering will need to be very accurate so that the sleeve does not shift as it goes into heating cycles.

First prize is a new block obviously.

Looking forward to the build.

Thanks Pete. Yes lots and lots off debate on iron cylinders in aluminum blocks. Westwood manufactures them in the UK and they have a good reputation so ill use their iron if im going.

RS autosports already sent me in the right direction wrt engineer as the fitting is crucial. They freeze the cylinders and heat block for an interference fit.

Hartech does wet nikasil cylinders. Best in the world. Comes at a price but less than I thought. They supply and fit wet cylinders, new pistons and performance bearings.

Most parts will be ordered from design 911 in the UK.

 

[Katanator]

From my shopping around this is probably the only route I would go if buying the 997 3.8. Just too much risk of bore scoring if paying top dollar. Its almost a case of when than of if.

Forgot to mention IMS already been replaced with double row ceramic bearing.

 

[Katanator]

Tempted to pour 10w60, new sparks, ceratec, and drive for a few 100kms to see what actual oil consumption is.

 

[Peter@AEW]

Two things on liners
1. The concentricity of the outside diameter of the liner is absolutely crucial with runout being in 0.00xx
2.The speed of the reborer as well as the quality of the cutter and proficiency of the operator as a lot of heat is generated which can effect the block.
The methodology of inserting liners is pretty standard across the industry however the medium used can vary greatly with dry ice and warmed block being the go to.
Again the extent of the "warmup" needs to be done to a formula of sorts which I have no knowledge of as that prevents the block from distorting.

Not wishing the labour the point just highlighting some areas that may require further investigation.

As to you exploring the ceratec and fresh oil option I would encourage you to restrain your urge and rather pull the engine.

It is not unheard of to have a chunk go walkabouts either from piston or bore...just saying

 

[Benji]

This makes me scared of owning a 997, but I still want one

Sorry to see the scoring, btu will make a nice project. How does this compare with the Z4M?

 

[Katanator]

This makes me scared of owning a 997, but I still want one

Sorry to see the scoring, btu will make a nice project. How does this compare with the Z4M?

Lol have not had the guts to push the 911 and enjoy, the tapping goes away under load.

As said this is the only route id own a 997, or alternatively very low mileage with pristine oil change history and bore scoped bank 2.

Strange enough oil filter was super clean and compression on cylinder 5 and 6 the same with healty levels. But the signs were tapping noise, wet exhaust manifold gasket, burnt spark plug and ultimately bore scoped evidence.

 

[Katanator]

Two things on liners
1. The concentricity of the outside diameter of the liner is absolutely crucial with runout being in 0.00xx
2.The speed of the reborer as well as the quality of the cutter and proficiency of the operator as a lot of heat is generated which can effect the block.
The methodology of inserting liners is pretty standard across the industry however the medium used can vary greatly with dry ice and warmed block being the go to.
Again the extent of the "warmup" needs to be done to a formula of sorts which I have no knowledge of as that prevents the block from distorting.

Not wishing the labour the point just highlighting some areas that may require further investigation.

As to you exploring the ceratec and fresh oil option I would encourage you to restrain your urge and rather pull the engine.

It is not unheard of to have a chunk go walkabouts either from piston or bore...just saying

Will take up the advice on further driving, probably not worth the risk.

Below is the procedure as sent from Westwood to me:

Interference for the liners into the block is 0.038mm +0.0127 / -0.000. The liners need to be cooled/frozen and the block heated.

Make sure that the bored finish on the block is very good, maybe honed before fitting the liners.

After the liners have been fitted and the temperature equalised, press the liners down to make sure they are seated on the flange.

Bore and hone the liners to the correct piston size, then……..press the liners again to make sure that they have not lifted a small amount (This can happen).

Now face the block completely flat.

Here is the liners im considering:

https://www.design911.com/p/ductile-iron-cylinder-liners-porsche-997-38l-c2s---c4s/

Along with these pistons:

https://www.design911.com/p/engine-piston-set-for-cast-iron-cylinder-repair-liners-porsche-997-38l/

And ofcourse the cats must go, they will probably be partially blocked already:

https://www.design911.com/p/exhaust-catalytic-converter-bypass-x-pipes-designtek-for-porsche-997_2_2/

 

[Katanator]

Still need to figure out how im going to get enough height lift at the rear to drop the engin the most cost effective way.

 

[Katanator]

Here is my initial order list for the rebuild, planning to replace water pump, thermostat, air oil separator whilst im in there.

Adding 1 or 2 spares of valvetrain components and injectors incase its needed.

SKU	Product Name	Quantity
99610593900/1	Intake valve spring. Porsche 987 Boxster / 987C Cayman / 996 / 997	2
C4008	Engine timing tool kit - for Porsche 986 Boxster / 996 / 997.1 / 987.1 Boxster / Cayman	1
99610527304/2	Exhaust valve. Porsche 996 3.6L / 997 3.6L / 997 3.8L / Boxster 987 3.4L	2
99610527102/1	Inlet valve. Porsche 996 3.6L / 997 3.6L / 997 3.8L / Boxster 987 3.4L	2
90021900930/2	Engine Oil Drain / Sump Plug (M18 x 1.5) for Porsche 986 / 987.1 / 996 / 997.1	1
999100M9701	ENGINE GASKET SET Porsche 997 S 3.8L 261KW / 355HP M97.01	1
98710525401	Camshaft bolt. Porsche Boxster / Cayman / 996 / 997.1	2
99610514500/1	Valve spring retainer upper. Porsche 987.1 Boxster / 987C.1 Cayman / 996 / 997.1	2
99610418059/2	Cylinder head bolt long, Set of 12. Porsche Boxster / Cayman / 996 / 997	2
99610512351	Exhaust & Intake Valve Collet. Porsche Boxster / Cayman / 996 / 997	6
99710703801/2	Oil separator main centre. Porsche 997 3.8L C2S / C4S	1
95510567500/1	Oil stem seal. Porsche 986 Boxster / 987 Boxster / 996 / 997	24
99610111562	Crankcase main bolt M9x127. Porsche Boxster / Cayman / 996 Carrera / 997 Carrera	14
99610512154	Washer valve collet. Porsche 986 / 987 / 996 / 997.1 / 955	2
99711152000/1	Exhaust sleeve catalytic converter to silencer. Porsche 996 / 997	2
99610601361/4	Water Thermostat with Insert - 160F / 71°C Low Temperature. Porsche 986 Boxster / 996 / 987 Boxster / 997	1
99710601106/1	Water pump. Porsche Boxster 987 / 987C Cayman / 997 C2 / 997 C4 (non Turbo)	1
3606109976	Exhaust catalytic converter bypass X-Pipes DesignTek for Porsche 997	1
99760512300/1	Fuel injector. Porsche 987 Boxster / 987C Cayman / 997	2
99610514700/1	Valve spring retainer lower. Porsche 987.1 Boxster / 987C.1 Cayman / 996 / 997.1	2
L3544/48	Ductile Iron cylinder liners Porsche 997 3.8L C2S / C4S	1
99710713800/1	Oil Separator for breather lines Porsche 997 3.8L C2S / C4S	2
197837098	Engine piston set for cast iron cylinder 99mm bore repair liners Porsche 997 3.8L	1

 

[AshG108]

Gees,
This is mostly greek to me but subscribed for sure as this will be a great learning curve!

All the best bro!

 

[Peter@AEW]

Gees,
This is mostly greek to me but subscribed for sure as this will be a great learning curve!

All the best bro!

Aren't you lucky that I can translate for you what with Greek being my mother tongue.

 

[TurboLlew]

Really looking forward to this build. Hats off for saving another special car as a labour of love!