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Tomy's Avatar
 
Join Date: Jan 2002
Location: Porsche World
Posts: 380
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oil leaks and what happen...

I had have some oil leak problems before but let say it was so small and it was not issue. But last autumn I decide to change my original turbo to k27 7200 as well as put less restrictive muffler so I put toys from Brian RLY8 ( nice work Brian!) the same time I take off around 150 kg out of my car. So results was perfect. I drive maybe 100 -200 mils and put my car for winter to my garage.
Just in spring I find much higher oil leak and first problems with clutch. So I make some clutch adjustment and find it work. But some more troubles comes. First I find that boost going to high. Even 2-3 times I had have cut off on second gear on around 5000 or 6000 rpm. Ok I find that something is wrong but still my 930 was going perfect. Oil leaks going to be too high so I decide to see what is going on. I put my car to official Porsche service where I have some friend to see what is going on.



Before we take off engine we find that it is oil in IC as well as it seems that turbo oil gaskets leaks ( maybe 500 mils on new turbo) . We finally removed engine and.... see pictures - I have bigger work to do than I expected.



1.Why oil is in IC and intake? - blow up Turbo?
2.OIL leaks on heads /crankcase all gaskets to be renew ( 700$ -all gaskets) but why too high boost blow up gaskets or ?...


3.What do you think when you see this pictures ? any suggestions?
Buy the way I will install new clutch as original clutch is in bad shape.
I start with small leaks ...
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Old 09-21-2011, 10:21 AM
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I will be in this boat as soon as I get the car to its new home
Old 09-21-2011, 11:53 AM
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Ok some fresh pictures after dissasembling.







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TET930 996 TT 2003 X50 996 GT3 2004
930 1988 black on black -fast...
944 TURBO S 1989 WHITE/BLACK # 1 944 TURBO S 1989 #2
911 S 1970 Targa /ex porsche werks car!
911 S 1969 Targa (under rebuild)
Old 09-21-2011, 01:02 PM
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So time goes and I take my car back from Porsche Centrum on 13.12.11. What was done?
PC disassemble engine and make all measurements - I was so happy to see that all numbers are according tolerance and let say my engine is like new condition. But with 90T miles on it I decide to put new rings as well as new valve seats as engine was apart.


Also I find that clutch is in bad shape ( I push my car hard many times when it received Brian free flot exhaust and bigger turbo unit)



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TET930 996 TT 2003 X50 996 GT3 2004
930 1988 black on black -fast...
944 TURBO S 1989 WHITE/BLACK # 1 944 TURBO S 1989 #2
911 S 1970 Targa /ex porsche werks car!
911 S 1969 Targa (under rebuild)
Old 12-17-2011, 09:12 AM
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So it cost much more than I expected as it should be only oil leaks work...and I ended with:
-disassembling and assembling of engine
-oil leaks work
-new valve seats
-measurements work
-new oil 2 times
-new filter 2 times
-all new gaskets ( make money...)
-new rings
-all metal air ducts renew
-all air deflectors renew
-new clutch
-rebuild new turbo - and it was biggest mystery as I had new turbo since maybe 700 miles but it looks that something small ( metal screw? leave by machanic mounted this turbo in summer) damage turbine .
-rebuild wastegate - rubber was damage and this accrue as I had have too big boost and probably this make oil leaks on cylinder to head place
IMO all screw keeping together cylinders and heads was not screw it. As my engine was 90T miles it came loose and loose with higher boost oil start leaks when over-boost.
By the way I am happy that I find it fast and safe my engine!
IMO all high boosted engine or even hard driven normal boosted engine should be checked every 25T miles and screw it head screws as well.
-all hardware new
-all air ducts new
-new plugs
-and clean everything!

But... my engine is like new and I am so happy!!! I need to brake in engine as fast as possible to finish before put my black bird in to the garage for winter sleeping.
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TET930 996 TT 2003 X50 996 GT3 2004
930 1988 black on black -fast...
944 TURBO S 1989 WHITE/BLACK # 1 944 TURBO S 1989 #2
911 S 1970 Targa /ex porsche werks car!
911 S 1969 Targa (under rebuild)

Last edited by Tomy; 12-17-2011 at 10:25 AM..
Old 12-17-2011, 10:23 AM
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The screw bouncing around the turbine, probably caused the oil blowback into the turbo and intercooler. Wastgate sleeve must have been on its way out, once the wg is open it's open not so not sure a small overboost would damage. Btw how much over boost are you having, sounds like boost creep due to a more efficient exhaust setup, and the wg can't keep up. I've got a similar problem going to some very short primaries, I'm hitting the overboost sensor in every gear, but man has boost gotten snappy.

From your pics it looks like more than 700 miles of head to cylinder leaking/baking, so chances are you got in there before any major damage occurred. Prob not what you wanted you spend, but this might have been much cheaper than catastrophic failure later if gone unchecked. Now you know you have good engine that will last another 90k. Be happy and enjoy driving the snot out of the car"

Ps more pics please...
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Old 12-17-2011, 12:08 PM
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Yes, I'm hitting the overboost sensor at lest on 2,3 and 4 gear till WG and Turbo rebuild.
I know I have fresh engine and like to drive this car as soon as possible. Now engine break in will takes next days and will put my car for "winterization" . But in March or April...
So probably I will do something with breaks and suspension for sure.
Next pictures on the way...
__________________
TET930 996 TT 2003 X50 996 GT3 2004
930 1988 black on black -fast...
944 TURBO S 1989 WHITE/BLACK # 1 944 TURBO S 1989 #2
911 S 1970 Targa /ex porsche werks car!
911 S 1969 Targa (under rebuild)
Old 12-17-2011, 12:22 PM
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