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997.1 turbo convertible DIY maintenance and exhaust build

 
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Old 01-07-2019, 09:50 PM
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997.1 turbo convertible DIY maintenance and exhaust build

Hi all,

i wanted to document my my work in this thread in case it might help someone else in the future. I also wanted a place to ask questions as I move along.

So I have a 2009 997.1 turbo that took me 7 years to find. I had been the best car I have ever owned and Iím planning to keep it for a long, long time. I do all my own work and I have been that way since I was 16.

Iím currently working on doing the plugs and building an exhaust for the car. I am doing everything myself except for getting some laser-cut flanges that Iím having made. Here is my progress so far:




It it has been fun working on it so far and it really helps me to learn about the car. I then found this build up near the bottom left part of the engine. There has never been a leak of any kind and I havenít lost any fluid. I was wondering if anyone has any suggestions as to what this might be.


 

Last edited by Edgemonty007; 01-07-2019 at 10:28 PM.
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Old 01-08-2019, 12:42 AM
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Well there has been a leak of something for sure. Could be spillage from above but doubt it. More likely a small leak from the tandem pump gasket.
 
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Old 01-15-2019, 07:01 PM
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Nice work keep us updated, will be replacing the BRV's (boost loss above 12 psi) and plugs very soon.
Nothing to offer on the leak my 996 would have oil sweat from the cam sensor gaskets.
 
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Old 01-16-2019, 09:10 PM
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So some slow progress to report. My Vibrant racing catalytic converters came in today. They are a true metallic core with 200dpi cell count. I have used these successfully on some of my other cars in the past so Iím curious how the exhaust will sound.



I also got got the passenger side plugs removed. Relatively easy with the right tools but my big hands were challenged to get into those tight spaces. Later this week Iím going to tackle the drivers side plugs.



I have not made much progress on figuring out where this leak and build up is coming from. I think Iím going to try and steam clean the area to see if I can find out where it is coming from. My flanges for the exhaust should be done by next week.
 

Last edited by Edgemonty007; 01-16-2019 at 09:20 PM.
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Old 01-17-2019, 02:39 PM
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Did you lower the engine to remove the plugs? found it unnecessary on my sons 996TT. What's your current mileage.
 
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Old 01-17-2019, 02:44 PM
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Originally Posted by jayi836 View Post
Did you lower the engine to remove the plugs? found it unnecessary on my sons 996TT.
the right side was simple enough as soon as you remove the servo for the variable vains on the turbo. The driver side is a very different story. Iím hoping to tackle that either tonight or tomorrow. I might end up lowering the motor a bit as mentioned in the Rockís DIY to give me more room. I have big hands and it has been a bit frustrating. But Iím taking my time with all of this. It is primarily plug and coil number one that is the issue. The other two are super simple with lots of access.
 
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Old 01-17-2019, 02:50 PM
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May want to inspect and lubricate the turbos BRV's, Just ordered a set as repair/ PM and hopes to fix the boost problem. I'm at 78K.
 
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Old 01-17-2019, 02:56 PM
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Could you share what lift you have looking at some now, is your garage underground? All I see is concrete.
Just started looking at exhaust like the Armytrix unit with gimmicky remote control, cant wait to see the final set up.
https://www.armytrixusa.com/armytrix...151461586.html
 
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Old 01-17-2019, 03:58 PM
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Good tip for the BRVís. Iíll get that done as well. Iím using a Max Jax lift. I have a 5 car garage at my house. 3 up top and a double under around the back. I went with this lift because it fits in my lower garage. I can get pretty much all of my cars 4í off the ground which is more than enough for me. It is the best tool I have and used the most.
 
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Old 01-21-2019, 09:46 PM
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So got some steam cleaning done to try and find out where the leak is coming from. I think it is coming from the variocam gasket. I have spent a fair bit of time cleaning to see. I will watch it over time.




 
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Old 01-21-2019, 10:47 PM
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Good luck finding the leak. I now want to steam clean my engine...
 
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Old 01-22-2019, 10:56 PM
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I had a similar leak. The leak could be form this screw???
 
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Old 01-23-2019, 08:25 AM
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Not sure that is a good idea. I can't remember where, but I recall reading about there being a coating on the engine to prevent corrosion that would be removed if you steam cleaned or used a harsh cleaner to clean the engine.

Ed
 
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Old 01-23-2019, 08:33 AM
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Old 01-23-2019, 10:40 AM
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Thanks Coquitlam! for the insight. Now that I look at your pictures and compare to mine, I think I might have the same problem - oil build-up seems to be concentrated around the same area. We should meet up at cars and coffee sometime - I live in Port Moody!

Thanks Iliejk for the cautionary note about the coating. I agree with you about the corrosion resistance but I do need to find out where this leak is coming from. I'll pursue some form of coating re-application once the problem has been diagnosed and repaired.
 

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