Porsche 911 (996) C4 - Complete Engine Rebuild

I bought a Porsche 996 C4 with piston slap, and rebuilt the engine over the winter. Amazing experience!!!
I replaced the pistons, and had the cylinders sleeved. I also replaced the IMS bearing, AOS, water pump, all coolant hoses...just too many parts to mention. I didn't take too many pictures during the removal process because I didn't think I would document the procedure. I took more pictures during the assembly process and I think the clip demonstrates that. This video clip basically summarizes the work performed. This is the 2nd revision of the clip.
In this version of the clip, I added footage of what the car sounded like when purchased, and removed music when demonstrating the engine sound after rebuild.

[@Fred82ndAbn]

Dated but still a great video! I also rebuilt a 2.5 out of a 99 Boxster (dropped cyl sleeve during startup, thankfully) back in 2009 and it ran me about the same, $5K ish. I used LN engineering back then when their re-sleeving didn't cost an arm and a leg. Now they want close to 5K for the sleeving alone. Great product but pricy for sure. I took the opportunity to bump it up to 2.9L using larger liners, JE pistons and a 996 crank. I also fitted an EPS oil-fed roller bearing IMS for good measure. It turned out pretty sweet and way more powerful than the stock 2.5. It was actually faster than a '01 2.9 a friend had, lol. I didn't replace the lifters or redid the heads. Just cleaned them up really well as the engine only had 25K when it dropped the cyl liner. I'm doing another M96 soon (swap into a 73 914). LA Sleeve seem to be the same guys. They maybe an affordable option. Cheers from Puerto Rico

[@Jeff_S.]

That's impressive Fred. Good luck with the new project. I dont know if the guy still works there, but it was Evolution Racing Engines at 45 Elm place in Amityville NY. If you google them, you can get the phone number. Again, I wish you luck!

[@al8161]

That engine really sounds smooth Sign of a well done job Congratulations

[@Jeff_S.]

Thank you Alberto, I appreciate it.

[@hansschweikert9153]

Insane. Would have loved to be a helper, to learn something this involved, but my brain hurts just watching this video, thinking about the how far you went into this and how many bad things could happen. I tip my cap to you for having the guts to do this dissection! I'm in awe. I think my '87 might be a little easier!

[@Jeff_S.]

Hans Schweikert .... lol thanks. could have used a helper actually :-)

[@JH-zy1dj]

You laid your pimp hand down on that one! Great work! I know the 996 has a few engine issues, but you are the man. Lets see more mechanic mastery.

[@Jeff_S.]

JOEY HAVLISCH - LOL, thank you Joey. Unfortunately my job does not allow me to take on more projects right now, but if I get any opportunity, I will definitely share it with everyone.

[@marcwilliams9285]

the amount of people that buy into the Porsche myth that only a specialist can service or repair them is crazy. its just another engine at the end of the day. can't believe you did all that and didn't closed deck the block though.

[@Jeff_S.]

Very good point....to be honest with you, absolutely nobody was talking about that on Porsche forums 6 years ago. I didn't even know you could on a 996.

[@pillayw126]

Jeff, Amazing job. I hope you have had the chance to enjoy your 996 now that the rebuild is complete.

[@Jeff_S.]

Thank you pilayw....I drive the heck out of it now. I saw both of your videos with your 996TT. Nice car! You should definitely make more videos with it :-)

[@Jeff_S.]

$1800 to have all 6 cylinders sleeved $1100 for JE pistons $600 to surface both heads and all valves $450 for all new hydraulic lifter $325 for new hybrid ceramic IMS $1500 everything else

[@Axel-ro7dn]

+Jeff Shal Wouldn't it have been cheaper to just replace it ?

[@Jeff_S.]

+Axel Van Uffelen No Axel...high milage used engines start at around $7,000 and fully rebuilt engines can go up to $15k to $20k...depending you the shop doing the rebuild.

[@Dap832]

does it feel like your making more power ?

[@Jeff_S.]

+Dap832 That's a great question...I wouldn't know because I towed the car to my house after purchase...I didn't drive it for fear of doing any further harm to the engine. I can tell you that the engine is "hyper responsive" now...even with an aging Tiptronic...but don't know what it was like prior to the work.

[@KSWA21]

+Jeff Shal Jeff bro, you should of video documented the whole rebuild! You owe it the community, and the newbs (like me) who want to follow in your footsteps! I want to buy a 1999, 996 Carrera with 267k on it for $16. Good or Bad idea?

[@ALT3REDB3AST]

Damn. I'm crying over a car video! Well done and saving this video for when I get my 996!

[@Jeff_S.]

ALT3REDB3AST - Thanks B3ast. Glad you liked the video.

[@Bobssecondhand]

Great job, Jeff. Funny thing - I have been working on engines all my life and have no fear when it comes to fixing whatever. With my Porsche (996 C4S, 2004), tho, I kinda find it a holy grail and am very hesitant to touching it. But seeing this, all the way to the keepers of the valves, I can almost feel the little click they make when snap into place - I got a renewed confidence. Its not different to any other engine. So - thanks. You restored my confidence. Cheers.

[@Jeff_S.]

Andreas Bergius - Thank you for the kind words Andreas. I am glad this video helped restore your confidence. I am having dinner with my wife, parents, and siblings (and their families), and read what you wrote to them....they all got a kick out of it. Again, thank you....Jeff

[@Bobssecondhand]

Jeff Shal Enjoy the evening with your family! Love from Sweden.

[@johnkirchner5130]

One Word... AWESOME! Well done my friend!

[@Jeff_S.]

Thanks John. I appreciate it.

[@Photoandcargeek]

Great job. The 3.6l engine is so much noisier at idle! There are companies (such as Autofarm in the UK) who do full engine rebuilds and, whilst fixing cracked cylinder issues, they can increase the engine capacity to 4.0l (and 400bhp) before relining with much harder liner than the original.... but then you have a modified 911 which you might not want to do if you are afraid of resale value. Once again, great job, great skills.

[@Jeff_S.]

Thanks

[@ajdahun]

A tastefully modded 996 is worth more than stock, especially if problem areas are remedied

[@Photoandcargeek]

ajdahun there are not many problem areas and the IMS issue is barely an issue nowadays. That being said I have a 996.2 with X51 and it is an awesome car.

[@ajdahun]

Agreed, highest number I've ever seen for failure was 8 % and that number was so high that it is an outlier, keeping oil topped off and frequent changes helps mitigate failure quite well.

[@Photoandcargeek]

ajdahun that was initially, now it is way way lower as some have died and some have had their IMS replaced before failure.

[@connect_music_yvr]

Well done!

[@AZdroptop]

Thank you for putting this together. Well done! Bought a Lapis Blue 02 C4 in Jan this year....Hoping I never have to do this. :)

[@Jeff_S.]

Rick Hutton - Thank you Rick. congrats and good luck.

[@markbarry1977]

Man i wish i had the skills to do this. Must feel so rewarding to finally start a motor you rebuilt with your own hands. I'd be too scared of it starting and then destroying itself. respect sir for attempting it.

[@Jeff_S.]

Mark, you hit the nail on the head. It was very gratifying and I still marvel at the accomplishment. I remember fearing the worst at first start. My brother was with me and I remember how he tried to instill optimism in me because I was fearing the worst all the time.

[@markbarry1977]

Jeff, had you rebuilt an engine before. Seems like a huge undertaking for someone with no prior knowledge or do you work in the automotive engineering sector. Either way well done!!!!!!

[@Jeff_S.]

+Mark Barry - Even though I have been working on cars since the age of 11, I never rebuilt an engine before. This was a huge gamble but I kinda had the confidence to tackle the job after seeing a KZbin video of a guy rebuilding a Boxster engine. What was even more reassuring was the fact that the porsche shop manuals are readily available and for a reasonable cost. After going thru the manuals I determined that it was doable (with the right tools) and began to hunt for a 911 with a bad engine.

[@cyfacrider2008]

Fascinating. My friend's 1999 996 just cracked a head and blew out all the oil and coolant. Calling around, shops are talking 10 grand up to 25 grand to fix it. I think most of the engine is fine, 70k miles, just needs a cylinder head. He's got about 25 grand sunk into the car, but says he's going to sell it as a roller for 6 grand. This video is exactly what he needs to emulate. (Are you in the mood to do another engine?) Recently, I rebuilt a BMW M10 engine in the driveway on the side of my apartment building, outdoors. When I was 19 I rebuilt a Porsche 912 motor in my parents sandy dirt driveway on a blanket. Ran great, drove it for 2 years and sold it. Amazing what you can do if you take a confidence pill and step up to something you believed was impossible. Such a cool video.

[@Jeff_S.]

Josh, I couldn't agree with you more regarding your last statement. I never did an engine rebuild before but was not intimidated to try....and again, I am still fascinated by the accomplishment...something I will treasure for the rest of my life. Congrats on the M10 rebuild...one of the best parts about doing a complete rebuild by yourself is knowing that you did the job right and nothing was left to chance and no unnecessary shortcuts were taken. Shame about your friends car....if you can convince him to sell for $5k, I may take on another project :-)

[@cyfacrider2008]

Agreed about doing your own work, as it was my own car, which I would be driving for years, I tended to be obsessively meticulous in every step. Also, without time constraints, you can stop and do research, find out the best practices and the trick mods and upgradable parts. And if you're not sure you did something right, just take it apart and start it over. I've driven my rebuilt BMW to up to Denver and the rockies, laguna Seca and Pebble Beach, San Diego and up the 395 to the high sierra many times. As well as the daily madness of LA stop and go traffic. No problems in five years of hard driving. By the way, what kind of torque wrench did you use? I've used a $25 craftsman beam type wrench for years, seems to do the job. Most of my tools are snap-on otherwise.

[@Jeff_S.]

Lol...I agree with everything you stated...I think you and I are a lot alike. I used an AC Delco electeonic torque wrench adapter. I checked it against my dad's snapon torgue wrench and it was spot on. I am so paranoid that I would actually check it against other torque wrenches throughout the process and triple checked every nut and bolt.

[@DasCayman]

you guys are heroes

[@yeliab67]

I am seriously tearing up. Nice job.

[@Jeff_S.]

Boseman 67 - thanks

[@6x6Tortuga]

Nice work Jeff

[@Jeff_S.]

Thanks Bryan.

[@alanstorey5579]

Excellent job. Would love to be able to do that.

[@jimmytheslacker]

This is amazing. How many hours did it take?

[@thecrazykartbyAJ]

Impressive! Congratulations for all the work!

[@Jeff_S.]

Joe Carmona - Thanks Joe.

[@911TVR]

Did the mpg drop dramatically after the rebuild? I’ve had mine done and it’s using 20% more now. Hoping it’s bedding in time!

[@Jeff_S.]

@ Steve Franklin... they are not that bad...what helps a lot is the fact that the shop manual is readily available and the various Porsche forums (Rennlist, Renntech, PelicanParts...) with real pro's providing advice.

[@dougutubewilson]

Wow. I'm so impressed. Such talent.

[@Jeff_S.]

Thanks Doug. I appreciate the kind words.

[@Peter10654]

Amazing for a backyard garage job !! GREAT WORK !!

[@Jeff_S.]

Thanks Peter.

[@christophercolby2202]

Well done!!! Sounds beautiful

[@Jeff_S.]

Thanks

[@jstam3780]

Interesting video. Liners still doing their job well?

[@Jeff_S.]

Yep

[@jstam3780]

What is the mileage you have on the rebuild now?

[@Jeff_S.]

@@jstam3780 about 10k...only drive on weekends

[@jstam3780]

No oil usage yet?

[@Jeff_S.]

@@jstam3780 nada, no leaks anywhere either...using motul 8100

[@anilec333]

Wow the ending is all the part number!

[@gregwhaley4017]

Jeff, great job and thanks for sharing! You have possibly inspired me to take on my rebuild, as piston slap on the right side seems to just be beginning @ the 84k mark. My question (for now) is, how much of a price increase would you imagine for increasing the 3.6 up to 3.9 or 4.0? Thanks in advance, if you have time to reply. Best wishes!

[@Jeff_S.]

Hi Greg. Thanks for the compliment. I don't think there will be a price increase for going to 3.6....off hand, I can't think of why there would be.

[@gregwhaley4017]

@@Jeff_S. well, I'm already at 3.6 factory displacement and considering a move up to 3.9 or 4.0 but mainly wondering if I would need to use upgraded connecting rods (which could be a substantial additional expense over reusing the stock rods) for that, and whether there would be much of a cost difference between standard sized pistons & oversized with matching cylinders. I will probably research that a bit more. As well as read through your video a few more times to become more familiar with everything involved. Thanks again!

[@Jeff_S.]

@@gregwhaley4017 Sorry, I missed that point...I thought you were at 3.4....I had my pistons custom made if I recall....price difference should be tiny if at all....here is my concern and the reason I didn't bump up from 3.4....the cylinder walls and casing are so fragile already (seemingly), I didn't want to risk changing displacement at all and potentially decreasing thickness of cylinder wall...you know what I mean. I didn't want to do anything to change already questionable tolerances.

[@Wamzish]

Jeff, I am impressed and inspired! Good Job!

[@Jeff_S.]

Thanks Wamzish

[@shaneswanson1938]

Great job! Nice K-75S too

[@Jeff_S.]

Thanks Shane.

[@dennisdamenace214]

I commend you sir. Great job and thanks for posting.

[@Jeff_S.]

Thank you for the kind words Dennis.

[@stevefranklin8452]

Great video. Are they difficult to work on? On the face of it, the engines seem to break down quite simply....

[@meschio]

much appreciated. Have a nice saturday night

[@cosminpopa8630]

Now that is awesome. Excellent Work!

[@Jeff_S.]

Thanks Cosmin

[@f1knight]

Congratulations, enjoyed watching that!

[@Jeff_S.]

Thank you Carlos

[@vstol]

Hello Jeff. Thank you for your efforts in making this video. It is very much appreciated. Your kind reference to Glenn986s is acknowledged and will be followed up. Great rebuild and the result must have been very rewarding.

[@fastrandstrongr]

Amazing job and great taste in music. Congrats!

[@Jeff_S.]

fastrandstrongr Haha....thank you.

[@jonmashburn1656]

Cool video. Muse was a nice touch also!

[@Jeff_S.]

Thanks Jon. I am a huge fan.

[@colinteoh3230]

Amazing job, congratulations.

[@Jeff_S.]

Thanks Colin.

[@MrKaiKai]

WOW very impressive, you have motivated me. I have 997s which has started ticking at 133k miles. wondering if i can do the same thing.

[@Jeff_S.]

Thanks....just be certain that the ticking is not something minor prior to taking on something like this....

[@BaxterRoss]

Amazing video, thank you for sharing. Can you please let us know how your steel liners are holding up? Thanks!

[@Jeff_S.]

Thanks Baxter. I appreciate it. I am pleased with the liners and have no complaints....having said that, it's my weekend car and I still have only about 6k or 7k miles on them (I live in NYC).

[@Turboy65]

So what did all the parts cost to do this job? Not counting the cost of the car, of course.

[@themedic4050]

8k

[@michaelbender1226]

Impressive Job..! Well done.. 👍

[@Jeff_S.]

Thanks Michael.

[@javiertorres6995]

Hi Jeff, I have a similar problem, albeit not as extensive, with my 2004 C4S and from the depths of my automotive despair...your video is a beacon of light. My challenges are that I an mot mechanically inclined, have no tools and am in Chile where no one will touch the car with a 10 foot pole saying that at most they will remove the engine and put it in a crate so I can ship it somewhere where the work can be done. Also, I am told that without the original Porsche scanner, the ECU will die and the engine will not work when I get it back. What did you do about the electronics? did you keep the ECU energized? did you have any issues with the immobilizer or sensors? My heartfelt thanks for posting the video and congratulations on your amazing work. You rock dude!

[@Jeff_S.]

Jav Tower I am so glad it was helpful for you. My 'beacon of light' were the videos on KZbin posted by Glenn986s. if you haven't done so already, please check them out....he did an incredible job. just an fyi...I had no power going to ECU for more than 6 months and no ill effects. You should post on Rennlist any questions you have with regard to ECU compatability. They have some pretty solid experts there. I wish you luck with your car and thanks for commenting on my video. I appreciate the support and kind words...Jeff

[@yongzhi8180]

It was a great rebuilding video, may i ask you are the piston bore still the same 99mm or is it bigger? And the part that sleeved all 6 cylinders means sleeved the cylinder repair liner?

[@Jeff_S.]

Hi. Sorry for the delayed repsonse....I kept the piston size stock and the cylinders were sleeved (not coated). Hope that answers your questions.....Jeff

[@yongzhi8180]

TQ for your reply ya

[@MikeKleinsteuber]

Nicely done.

[@Jeff_S.]

Thanks Mike.

[@RedondoBeach2]

Jeff, you and your bother did a great job. Thank you for making the video and sharing it with us. If you don't mind, I have some questions. 1. What experience did the two of you have with rebuilding engines/transmissions before starting this project, and on what vehicle models? 2. How much familiarity did you have with this engine model before starting? 3. Approximately how many hours of work went into the year long project? 4. What part of the rebuild was most challenging or difficult, and why? 5. When the engine was removed, what opportunistic maintenance was done inside the engine bay or any other part of the car, if any? 6. What maintenance manual did you use, and was it sufficient or did you need to source information/expertise elsewhere? 7. Can you give an update on how many miles are on the rebuilt engine, how it's running, and what follow-on engine/transmission maintenance might have been necessary since the rebuild? 8. What lessons learned do you have from the rebuild? Thanks again for the video. I don't own a 911 but would like to buy a used 997 within the next few years. Before that happens, I want to learn as much as possible about the cars.

[@Jeff_S.]

RedondoBeach2 - oh man that is a lot of questions...the good news is that I have them all answered already ;-) please read thru all the questions I answered for this video and if you need any more info after that, I will do my best to provide it....thanks again for looking at the video....Jeff

[@RedondoBeach2]

Jeff, I apologize. I should have read all of the Q&A before listing questions. I did that at this point and have a better understanding. The work you did is especially impressive considering it was your first rebuild. My original assumption was that maybe you were an experienced Porsche mechanic. I also had this thought in my mind that there's no way a DIY mechanic and do this level of maintenance on a modern engine...especially a high compression/percision-tuned Porsche. You proved that it can be done. I was a mechanic for 10 years but that was almost 20 years ago. My experience was on aircraft turbine engines, not reciprocating engines. Piston engines are a whole different beast. I'll view the videos by Glenn986s that you mentioned and also have a look at Rennlist.

[@Jeff_S.]

RedondoBeach2 - No need at all to apologize. Your questions are all spot on that is why I always make it a point to respond to everyone. I know that when I was doing my research for the rebuild, I had all the same questions you asked, and then some. Let me know if you ever need any clarification with anything, I will be glad to help any way I can....Jeff

[@Kongzi93]

Nice job! Respect. Hope I will never have to do that on my 1999 996 mk1 C2. It has 130k(km) on it. Runs and shifts just fine, sounds great. This engine has never been worked on besides regular maintenance. Do you think I is better to take preventive measures to replace the IMS,RMS,AOS, and do the watercirculationMOD?

[@Jeff_S.]

Thank you Philip... with regard to preventive maintenance, I think I would just recommend that you change your oil every 3 to 4 thousand miles and make sure you have clean radiators to prevent any overheating issues.

[@Kongzi93]

+Jeff Shal Thanks for your reply . Will do so. Hope to enjoy my 996 for at least 5-10 years. I will keep you posted.

[@kennethbehrman6998]

Nice work Jeff! I'm currently about to embark on a similar journey due to non-ferrous metal in the oil pan. Do you happen to have a list of specialty tools you used? Any resources besides the obvious that were essential to your success? Thanks!

[@Jeff_S.]

Kenneth, I had to pick up the porsche timing and piston pin circlip insertion tool kit off Ebay for around $300 (the made in China version). I also needed to get the IMS puller and drift for around $100. I had to make my own variable cam actuator hold down tool by buying a reverse threaded rod and 4 nuts (i forget if it was 8mm or 7mm). As you saw in the video, I also made my own RMS install tool. Lastly, 1 of the several bolts that attach the transmission to the engine was an odd 8 or 12 star configuration that are German car specific, and I needed to purchase that seperately. That's all that comes to mind right now...the rest of the tools were in my garage already (other than the piston ring compressor tool $10 and the torque angle wheel/guage $10).

[@razvanyke]

Very nice work man !

[@Jeff_S.]

Thanks.

[@tripletramptrident580]

Hi Jeff. I have the exact same situation with a 2002. Your post is a great help. What I would like to know is where you obtained the sleeves (brand) and did you go with the stock 100mm pistons or 102mm? Thanks man, great post!

[@Jeff_S.]

Hi Tripletramp. wish you luck with the rebuild...I used sleeves from 'LA Sleeve' and pistons from 'JE Pistons'. I used the stock size (I believe it is 96mm in my case because I have a 3.4L...yours is 3.6L which would equate to 100mm??). I used the OEM size because I won't be racing it. I also have another reason....we have all heard of the "D-Chunk" issues with cylinder walls on these engines....my unscientific thought was that if I increase the bore, I have to thin out the walls....I don't want to do that and (as I perceive it) have a detrimental effect on cylinder wall integrity and maybe enhancing possibility of D-Chunking. Not sure if theory is valid, but didn't want to test it. I wish you the best of luck...it isn't easy but so damn gratifying 😊 and gives you 20k viewes in 9 months.

[@tripletramptrident580]

+Jeff Shal - thanks Jeff it is most king of you to respond. You are right the bore is 100, I have heard of a kit that is 102 and makes it 308. I think your intuition makes sense athough you now have iron liners not aluminum/Nikasil so it would be stronger. Just a thought. Wont be racing mine either.

[@vikas150]

I bought a 996 a year ago so far at 105K i did the wheel bearing yesterday -- thought it was going to be more of a project car but its my daily driven

[@Jeff_S.]

+vikas yes, surprisingly resilient. I am in New York so won't be driving it year round because of our winters, but If I were down south or west coast, then I would as well. They are a joy to drive.

[@vikas150]

I'm in long island too actually

[@Jeff_S.]

+vikas patel Vikas, I didn't know that...hello Neighbor ☺. My car spent most of its life in Arizona so it doesn't have any rust on it...I am apprehensive to drive it here during winter because of all the salt used. I kinda want to keep it rust free.

[@vikas150]

+Jeff Shal mine has been in the northeast all its life and It's been pretty free of rust --- salt will stick to the bottom of the car but I drive it everyday so rain washes it out -- holding up perfectly considering the age and usage I think the first two owners garaged her and the guy I bought from didn't as he was in the Bronx and I haven't because mine full of junk -- are you a pca member

[@Jeff_S.]

+vikas patel No Vikas, not a member but considering it.

[@christopherheppingstone2729]

great watch and was wondering how many man hours did that take??

[@Jeff_S.]

That is a great question. I did this work on Sundays over a 6 month period (Nov-Mar). There were some Sundays that I worked for 10 hours straight and others that I didn't work a single minute. I think I can do this work again next time in about 40 to 50 hours. I can tell you for sure that cleaning engine parts and double & triple checking torque values took the most time (not taking into consideration dealer part delivery times)...

[@Michael-st9ky]

Your new piston looks shorter, did you have any problems? loss of compression or power etc

[@Jeff_S.]

Nope. None whatsoever....They were custom made and my guess is that the factory compensated for any piston skirt variances with the placement of the wrist pin? Thanks for watching the video.

[@Michael-st9ky]

@@Jeff_S. Makes sense, it looks good

[@1cbread]

Great video

[@Jeff_S.]

Thanks

[@ranchlazyo]

I think a set of webers would look cool.

[@hansschweikert9153]

How exactly was the engine crane used, to lift the car higher or...? I very much enjoyed your video.

[@Jeff_S.]

Hans Schweikert Excellent question Hans. I wrapped a heavy chain around both bumper shock absorbers, locked the chain together with a heavy duty bolt, and lifted in the middle of the chain.

[@hansschweikert9153]

Jeff S. So it was to get the car up higher, right? Another question: Cylinder scoring was a known issue that developed with some 996's. What was the cause, and what will prevent that with your new set up? And is it still running well? Thanks for your time, and for the knowledge base you've added to the Porsche community at large.

[@Jeff_S.]

Hans, Thanks for the encouraging words. The car is still doing great. I bought the car in that condition and read thru the owners repair receipts. The last work statement claimed that the oil they replaced appeared to have "dirt" in it. My sense is that the previous owner didn't replace his oil regularly. That combined with poor cooling probably contributed to the cylinder scoring issues. My hope is that this will not happen again because I used iron sleeves and not the Nikosil coating. I also plan to keep the car properly cooled and change the oil every 3k miles (once a year for me as I only drive the car on weekends).

[@NikolasKourtidis]

Hey Jeff, nice work. Do you have the part list as Excel or other document?

[@Jeff_S.]

Nikolas Kourtidis .... Hi Nikolas, yes I do. Give me your email address and I will send it to you.

[@estebanfigueroa746]

Hi Jeff, love the video, can I also get the part list? Email is [e-mail]

[@arnoldmosk494]

Biggest problem is that the first owners of these Cars don’t give a damn about a proper warming up on these engines. Put in a DOF IMS solution , change the thermostat and waterpump and for heavens sake warm up that damn engine. These engines are trouble free if you treat them well !!!

[@mikefranky]

So true....I had mine only 6 months and then the dreaded piston slap.....repair bill £6500!!

[@isaacmireku7094]

Great Video!!!

[@Jeff_S.]

Thank you Isaac.

[@noobowner358]

if you are interested in working on a boxster 3.2 project, i have boxster s with a rod bearing problem

[@Jeff_S.]

harman dhillon ...LOL. I will think about it.

[@ivanmamedov90]

As I know je pistons don’t produce pistons for 996. Do you order custom pistons?

[@Jeff_S.]

Yes. I had a hard time finding pistons in stock 3.4L specs. If I recall, Mahle had them but I just couldn't find them at a good price point....I reached out to EBS racing out in Nevada and I believe they had them custom made (Not sure how it is now, but back then it was not a common item on the shelf).

[@ivanmamedov90]

@@Jeff_S. Thank you for answer. I also mentioned that new pistons a little bit lower than old ones. It's piston stroke changed? Or it's just lower the connecting rod of the piston is connected with the adjustment for this piston height?

[@Jeff_S.]

I believe it's only the skirt that is slightly shorter which should be negligible.

[@chipbirdiestone8815]

Ok that's impressive.

[@Jeff_S.]

thanks

[@Jeff_S.]

+Mike Brink Mike, I wish someone would have published the videos you suggest...would have made life so much easier for me. The manuals I used were not the latest, so I had to hunt down updates and updated torque values and such. I also used the Rennlist community to ask questions and get clarification on things I didn't understand. The bolt breaking off was completely my fault...I used the wrong pulley bolt and over torqued it. Was glad I didn't crack the case.

[@Jeff_S.]

***** in regard to what caused the original damage, I am guessing the owner didn't do his oil changes in a timely manner...it could be dirty oil or driving while overheating...

[@sergiocarlos1722]

nice jobe well done congratulations

[@Jeff_S.]

Thank you Sergio Carlos

[@rocketbob]

Curious how well the cast iron sleeves are working out. Were they Darton sleeves?

[@Jeff_S.]

Bob Japundza .... Hi Bob. No problems whatsoever with the sleeves. They were purchased from LA Sleeve.

[@rocketbob]

Awesome, good to hear. I think any problems with sleeved or non-sleeved cylinders and D-chunk failures has more to do with how the tops of the cylinders are deburred after machining. I just had to pull a cylinder head on on my car to fix some bent valves due to the variocam bolt coming loose and I was shocked to find the tops pretty rough from the factory. Poor finishing there leads to stress cracks.

[@Jeff_S.]

Interesting observation Bob.

[@jdesousa1110]

What’s that engine assembly line you used??

[@Jeff_S.]

Hi Jonny, if you mean assembly lube....I used Redline.

[@jdesousa1110]

Lol sorry. I did mean lube

[@xtim0x]

Hi Jeff, what break in oil did you use?

[@Jeff_S.]

Hi Jorge. It was Brad Penn break in oil.

[@yeliab67]

Thanks

[@borutbozic9345]

so cool!

[@Jeff_S.]

Thanks Borut

[@mikefranky]

I had mine rebuilt roughly 3 years ago cylinders/pistons 4 5 6 replaced along with ims retrofit plus other work......final price £6500....;-(

[@Jeff_S.]

That is not a bad price. You did well.

[@mikefranky]

Jeff S. .....Engine been going well since would like to use it more but with this lockdown in the uk I’m pulling my hair out 🤦‍♂️🤣

[@Jeff_S.]

@@mikefranky same here in NYC (with riots sprinkled in throughout). This is very frustrating.

[@mikefranky]

Jeff S. .....Yes you guys got it all going on over there wish you the very best....Stay safe Jeff 👍

[@Engineerboy100]

Keep an eye out for my Light Savers Video, everyone with a 996tt, TurboS, C4, C4S or GT2 should have a set of these on their car. I have a set on my car ... obviously. video coming within 2 weeks. Light Saver video, look for it. ;)

[@mohamedabbes6064]

@jeff shal nice work reallydone there :o

[@Jeff_S.]

Thanks

[@kieranoloughlin]

Can you give us a hint at the overall cost of the exercise? :)

[@Jeff_S.]

Hi Kieran. I actually have the cost broken down on the comments here....read thru them and you will find it. One thing to note is that I had to pay pretty much retail for everything, and with Porsche....it ain't cheap.

[@kieranoloughlin]

@@Jeff_S. .... great.........thanks Jeff

[@Jeff_S.]

@@kieranoloughlin ...my pleasure

[@dasteufelhund]

HELL YEA!

[@huguesmisi3930]

Can you rebuild a 997 3.8 engine?

[@Jeff_S.]

I don't see why not :-)

[@meschio]

how many km before the rebuilt ?

[@Jeff_S.]

102k miles

[@macuser2]

Sweet

[@neal1275]

how long did it take to do it?

[@Jeff_S.]

@neal1275 ... I didn't really time it. I did it on Sundays over a 6 month period at a very leisurely pace.

[@yeliab67]

I am curious what you paid for a 996 with a bad motor.

[@Jeff_S.]

Boseman 67 - I purchased it on eBay for around $8k

[@mareksumguy1887]

So which model 996 911 did this engine come from??

[@Jeff_S.]

The car is a 2001 C4.

[@mareksumguy1887]

+Jeff Shal You used WAY too much assembly lube. That assembly lube is gonna get mixed in with the oil (obviously)and will make the oil too slippery to allow for proper piston ring to bore conformation. Thats why you want to use a shitty oil for break-in and change it much earlier. For street performance engine like this i would use cheap non-synthetic and do first oil n filter change at 300 miles. And keep using non-syn until fully broken in.

[@Jeff_S.]

+Marek Sumguy I think you make a valid point. As this was my first engine rebuild, I think I was a little overzealous with the assembly lube. However, I used less than one ounce of it in total, and when that amount is combined with more than 11 quarts of Brad Penn engine break-in oil (not a synthetic) required for a 996 engine after a rebuild, I would figure the adverse effects on piston ring seating should be close to negligible.

[@mareksumguy1887]

+Jeff Shal 11 quarts?!.... i had no idea they take that much oil!. Thats why i like to change the oil and filter shortly after a rebuild... to get the assembly lube out. You know... in the factories they don't use assembly lube... just engine oil for all bearings and valve train. Because of improved materials and surface finishes of modern engines... i don't think it's necessary to use assembly lube on these parts. But on high-torque fasteners... definitely use assembly lube. I think RedLine Assembly Lube is one of the best.

[@Jeff_S.]

Yea, Redline is what I used. 11 quarts is indeed crazy and makes for expensive oil changes :-)

[@Luistorres-wm4kb]

the music tracks names??

[@Jeff_S.]

I actually list the track names at the end of the video. Muse, U2, and Queen.

[@dean8644]

I wish i could do that

[@netkotreci8882]

3:24 New piston look a bit smaller :D

[@Jeff_S.]

That is to make them lighter :D The displacement is still a stock 3.4

[@netkotreci8882]

Jeff Shal Yes yes,but I was thinking about diameter of piston.Look at 3:24 ;look like that a left piston have a smaller diameter..I know diameter of both new and old piston is same,but on picture it doesn't look so. :D

[@Jeff_S.]

I know what you mean. It appears smaller.

[@scanspeak00]

I tip my hat to you sir. Are you a mechanic by trade or just a home mechanic?

[@Jeff_S.]

Thanks...I guess you can say I dabble....Never done anything of this magnitude before, but the factory manual made it almost feel like I was cheating :-)

[@zxtenn]

+Jeff Shal I had a friend who worked as a mechanic in a Porsche and Audi dealership in the early 80's even there only 1 or at best 2 could attempt a job like that, the dealer really only had ONE Porsche mechanic, manual or not you have excellent mechanical aptitude.Hope you purchased it cheap enough to offset all your time, effort and repairs, doubt a 911 with engine problems is every mans cup of tea

[@Jeff_S.]

jim dandy +Jim, thanks for the kind words. I really took this on as a challenge, like my own mount Everest. I was looking for a project car and was looking at 70s Corvette 's because of companies like Ecklers that have everything available to rebuild them, and at a very reasonable cost. What made me change my mind is that they really don't have much value, and that fiberglass body is not cheap to paint or easy to work with...I then saw a KZbin video of a guy rebuilding his Boxster engine...it was almost like a step by step guide. After viewing those videos, I decided to look for a 911 (has the same engine as a Boxster but retains value better). Found one on Ebay for $8300 with just the engine noise and jumped on it. Clean title, body and interior in great shape. Bought it (without telling wife) and the rest is history. The parts set me back about $6000, total ripoff but they charge for the name so... I can't tell you how many hours I put into it because I didn't keep track, but I tried to work on it every Sunday over a 6 month period. At the end of the day, it is the accomplishment that is priceless and will stay with me forever. I did the entire job on my own for the most part.

[@artmchugh5644]

Those engines may work well , but they are nothing to look at! 😄😄😄😄

[@6x6Tortuga]

totally agree. Nothing like the air cooled flat 6

[@kiiiburn]

U2 sucks. Wish this had video instead of a bunch of still images. Timelapse perhaps?

[@jessebondoc258]

can you do mine?

[@Jeff_S.]

Lol....

[@andrewlacroix3565]

Amazing job Jeff. Is that the Mark II engine? Are you driving the heck out of it now? I have done a few 996 videos - there are not enough of them on here considering how many 996's there are and how great they are to drive. I am extremely impressed and I am sure you will be good to go for a very long time with that car. Here is the run down I did on the 996: kzbin.info/www/bejne/rnerZJWLjcmJg6M

[@Jeff_S.]

+Andrew LaCroix Thank you Andrew. It's an MK1 and I am indeed driving the heck out of it. I saw all 3 of your videos, good job. Wish The test drive video was nice, made me want to go out and floor it :-)

[@Jeff_S.]

- "Wish"

[@lcaise]

really love 996 model but engine is a shame....

[@paulvarrieur976]

Be careful with the music you have chosen for copy infringement.

[@chevelle99xify]

what no cruise video, afterwards ! bla bla,, Nice work though !!!

[@Jeff_S.]

Thanks

[@hualni]

It's a shame the Germans use their powers for evil and savagery. They can make some incredibly beautiful cars and engines.

[@Blando7887]

a non-turbo model

[@Jeff_S.]

yes

[@Blando7887]

I wasnt dissing, it looks like you did a good job

[@Jeff_S.]

+Brandon Watkins I didn't take it as a dis...I thought you were asking if it was a turbo or naturally aspirated