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YOUR RESEARCHbeginning a project, starting with good news
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Fill adventure
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Performed · outcome unconfirmed · Original poster
Just separating the old injectors from the fuel rail was a wiggling, twisting, expletive-filled adventure.
Leading evidence: 'Fill adventure' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Clean can�t feel any roughness or play' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Performed · outcome unconfirmed · Original poster
As far as I recall, the PO installed an LN retrofit IMSB at about 72,000 miles, which was around 7 years ago.
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Performed · outcome unconfirmed · Original poster
Also removed and replaced the transmission mount bushing.
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Suggestion · Original poster
Old bearing out - looks clean, can�t feel any roughness or play when it�s in my hands.
Disconnect clutch hydraulic line, rather than futzing around
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Suggestion · Original poster
Elected to disconnect the clutch hydraulic line, rather than futzing around with getting the slave cylinder off.
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Suggestion
Might be too late, but if you had any grittiness or roughness when pushing the clutch pedal down, you might consider replacing the clutch slave cylinder.
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What started off as an awareness that my clutch was on its last legs (grabs at the top, some slight chatter) has snowballed into an engine-out update, and I'm ready to begin this weekend. The plan is to try and address as many "while I'm there" items as possible. The list of parts I've collected is;
Sachs OEM style clutch kit
LUK DMF
Porsche RMS
LN IMSB retrofit (the current LN bearing is 7+ years old)
Ultimate AOS
new Bosch fuel injectors
new Bosch starter + OEM cable
oil cooler o-rings (Porsche)
all 3 timing chain tensioners (Porsche)
Bosch crank position sensor (cam sensors were done recently)
Porsche coolant reservoir + cap
Bosch spark plugs (already has updated coils, not very old)
the waterpump & thermostat were done not too long ago
Anyway, the promised "good news" - before I start getting dirty, I figured I'd plug in the Durametric and do an "interrogation" like Jake's video. The car has seen some Range2 over-revs in its past, but over 600 hours ago. With a 40 minute freeway drive warm-up, cam deviations are +1.16 at bank1 and -0.48 at bank2. Rough running test showed some very occasional 1.6s, but mainly less than 1.0. Adaptation values were in the 1.xx range. At least I can assume I'm starting with a reasonably healthy engine.
I'll share pics here once I really get going. Meanwhile, wish me luck!
Sounds like it will be a fun project! Looking forward to seeing photos of the progress. I'd be especially interested in seeing the LN IMS after 7 years. Would you happen to know how many miles have been driven during that time? Lot's have been said about the service interval for these but not much hard data in terms of photos. My car had an EPS IMS bearing and it came out looking in perfect condition after ~50k miles.
Update:
the A/C compressor was tough, but I got it out. The P/S lines are really giving me a hard time, I�m going to move on and come back to them.
Almost forgot, I�m putting in a fresh transmission mount bushing too.
As far as I recall, the PO installed an LN retrofit IMSB at about 72,000 miles, which was around 7 years ago. I�m at 127,000 now.
Do you already have the tool? I rented it from a Rennlister when I did mine but I don't know if he's still around or if he's still renting the tool. The company that makes the tool (AGA) is in Escondido. Maybe they have a rental program...?
Dporto here on Rennlist has one that he offered to rent.There�s a local shop owner here in San Diego, and he�s offered to loan it to me, if he can find it.
With the transmission out, it doesn�t look like it would be too difficult to cobble together something to press a new one in.
Meanwhile, the P/S lines are still outsmarting me.
The Bentley manual has clear instructions for the ps lines. There should be several threads on the correct removal and few of really screeing them up. Do it right or it can get expensive
I have the Bentley and 101 Projects, but all they really say is that it�s tough. A search of this forum turned up a recommendation from Porschetech3 to use a flare-nut style crows-foot. Amazon next-day delivery to the rescue!
Story to be continued tomorrow�
While I eagerly await my delivery of crow-foots, figured I�d disconnect the fuel line. Only thing is, I can�t find where it attaches!
The pics in the Bentley book and 101 Project don�t look the same as my car. When I run my hand up and down the fuel line, I can�t feel it either.
Once again, Rennlist to the rescue. After a few different searches, I found someone else�s engine swap thread, and the 996.2 returnless system just has a quick-connect fitting, near the coolant reservoir.
Well, I got it out. Elected to disconnect the clutch hydraulic line, rather than futzing around with getting the slave cylinder off. We�ll find out if that was a smart move.
I�m hoping not to jinx myself, but so far I haven�t broken anything.
Degreased it (neighbors are gonna hate me), separated the transaxle, and removed the clutch/flywheel.
Clutch disc isn�t as worn as I expected, but the flywheel is shot! I can rotate the friction surface a noticeable amount, compared to the engine side. No sign of oil leakage from the RMS, maybe a tiny bit at the IMSB seal - they�re both going to be changed out regardless, don�t plan on ever doing this project again.
Putting it away�til next weekend
New weekend, next step of the project. Got the chain tensioners out. I�m a �belt and suspenders� kind of guy, so I locked cams on both banks. Moving the P/S lines out of the way, to access the tensioner on the passenger side, was a mild PITA. Old bearing out - looks clean, can�t feel any roughness or play when it�s in my hands. New one slid in easy enough.
Onward, Tally Ho!
Old and new tensioners
Old bearing, an LN single row
New bearing, in its new home. LN single row pro.
Have you seen the "Man in a Garage" YouTube series? He's taking his engine out and cracking the case following the Bentley manual. He's not a mechanic and doing it for the first time so he explains everything really well and shows each step in the video. It's very organized. I think he's going a lot further than you are but it might be good to watch if you get stuck on something. It looks like he's in Oceanside.
https://www.youtube.com/channel/UCEF...tQt95jYjFAVqPA
Starter with cable, oil cooler o-rings, new injectors, UAOS, all in today.
I can see how folks here have done these various items with the engine still in the car, but I can�t see how I would have done all them without a lot of collateral damage. After 21 years and 127,000 miles, many pieces did not want to go without a fight. Just separating the old injectors from the fuel rail was a wiggling, twisting, expletive-filled adventure. 4 of the upper o-rings on the injectors stayed behind, inside the rails - easy to extract with the engine out in front of me, but might have been an ordeal trying to work inside the engine bay.
transaxle has been reunited with the engine, new DMS flywheel, clutch, and release fork pivot all inside. Also removed and replaced the transmission mount bushing.
next weekend it all goes back in.
Might be too late, but if you had any grittiness or roughness when pushing the clutch pedal down, you might consider replacing the clutch slave cylinder.
Engine�s in, plumbing hooked-up, added some vital juices. Did the recommended crank-n-pause routine to get the oil primed. It started!
Gotta bleed the clutch, power steering and coolant, then I�ll put the back bumper on. Tomorrow.
Warmed it up a couple times, bled the clutch, topped off the power steering and coolant. All trim pieces back on. No new noises when it�s running. About 15 minutes away from a slake-down drive.
Just finished an 8mi test drive, took it to 6500 a couple of times. Everything works smoothly.
All that�s left of the project? - cleaning up the mess in the garage and putting away my tools.
Big thanks to the Rennlist community, the experiences shared in the forums and the products provided by the sponsors.
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