Top end rebuild - 996
 

I just bought a 1999 996 with a bad head gasket(s). Car runs smooth, idles smooth, but belches very white smoke more than Puff the Magic Dragon. Does anyone have any experience doing a top end rebuild on a 996 motor? Ive taken apart aircooled engines but this is my first attempt on a watercooled. Are they that much different? Can anyone point me to some resource on partial engine teardown? I'll probably post a WTB for a complete motor since that may be an easier route. Thanks in advance.

From what I can tell, 996 motors are very labor-intensive, require prohibitively expensive special tools, and go for a dime a dozen used. This probably doesn't assist with your rebuild, however. SmileWavy

I think you will find very little experience on this board for the water cooled engines. They are totally different from the air cooled. I wouldn't be afraid to try but you'll need to find out if parts are available and find a machine shop that will do the valve guides, etc.

-Andy

Elfer,

We've done a few of these engines and I can tell you several factory tools are needed to work on these things and thats a $1K+ investment.

You need the factory workshop manuals which will also list the tools needed to R&R the heads and cam housings as well as set valve timing.

Given the history of these early engines, my best suggestion would be to trade it for a new one at the dealer and get the benefits of some upgrades as well as a warranty.

Thanks for all the replies so far, guys. So, being new to the 996 scene, do you guys concur that my diagnosis is accurate and that conventional wisdom would suggest that coolant mix with oil, tons of white smoke = most probably head gasket. Engine idles fine, lots of power, no knock. Is there anything else that might be a possible cause? I just want confirmation that engine pretty much had it, and it will be either rebuild of replace. Does anyone know the prices for these engines for used and newly rebuilt, and possibly where to source them? Thanks.

I haven't seen any used ones lately. How much do these go for used nowadays? The only price point I have is from a salvage yard in No. Hollywood that has 1 in stock with 30k miles for $6,000.

You should check with your local dealer but Porsche used to sell these 3.4 replacement engines for under $10K, exchange and given the checkered history of these things, IMHO thats a deal.

Personally, I would not buy a used 996 engine from anyone.

This is sound advice.

Some of the reported water burning troubles in the 996 cars were documented to stem from cracked cylinder bores local to the head mating surfaces. There isnt a way to tell until you tear into it.

My experience here is that an engine replacement is the best bet for the $$. Current pricing for a "new" remanufactured engine from Porsche is $10.039.54 plus a core and the labor is approx $1520. (our labor rate is $98.00 here in southern NY) Our experiences show that the usual problems can include; dropped cylinders and or pourus castings along with intermediate shafts that have been known to break and wipe out the case.

We just puller another Boxster engine apart this morning to find that #1 cylinder sleeve had dropped.

Bill Rudtner

www.rudtnersracing.com

If you want to invest in the tools it is not a bad job. I have been building these motors since 02 and was on of the first to build the new TTs. If you want specifics please email or call me. I can help.

I PMed you with questions. I would sure like to get some info on this. Thanks.