Porschetech3

I thought I would throw together a basic path that would satisfy many DIY'ers for a 3.4 and also for a 3.6 M96.

Costs include a factory short block, sending the heads to a head service, complete gasket kit with all seals /o-rings/bolts ect. plus Loctite 5900. ( actually will have a few seals left over like front/rear main, water pump)

Head service would include cleaning, pressure testing, basic 3 angle valve job, new seals, light machining to ensure trueness cost is normally $250 each head..YMMV

This would take care of the engine internals, of course any worn out external parts coils,plugs, AOS ect, repair as necessary..

And you supply the labor.

M96/01 /02 /04 from 99-2001 3.4
996-100-951-TX Porsche factory short block from Auto Atlanta $6305.60
996-105-253-00 Vario cam guides from Auto Atlanta $21.66 need 2 sets
#1364363-M9601SET complete gasket set/bolts ect. from AutohausAZ $475.25
Part# 000-043-204-35-M258 Loctite 5900 from Pelican parts $14.00
$6838.26 parts
$500.00 cylinder head service
Total $7338.26 + your labor

M96/03 2002-2004 3.6
996100996UX Porsche factory short block from Auto Atlanta $7669.08
100904202 - O.E.M. M96.03 SET complete gasket set / bolts ect from Pelican Parts $660.75
Part# 000-043-204-35-M258 Loctite 5900 from Pelican parts $14.00
$8343.83 parts
$500.00 cylinder head service
Total $8843.83 + your labor

A much better alternative than buying a used engine IMHO

pdxmotorhead

So on the short block,, Just thinking here..
If I bought a set of nickies with pistons, and reused the rotating assembly except for bearings, I think I'd be in that ballpark?
As long as my current engine passed inspection that is..
And I'd add and IMS update of one sort or another most likely. so add the ~1800 dollar bump..

Porschetech3

Yea, probably a couple of grand more, I think I"ll do a quick workup using LN Nickies, with the added IMSB,main and rod bearings, timing chains, guides, rod bolts, ect. and see if it still comes in under 10k for the more experienced DIY'ers like yourself...

pdxmotorhead

Its sort of the basic, and a light upgrade option,, you'd always have to be ready for that un salvageable bit,,
Scored crank or bad IMS shaft , unuseable cams,, etc.

The nickies option would also give you a diy 3.8 upgrade if you wanted..
At some point,, you also still have to decide your abilities.. "A mans got to know his limitations" LOL

yelcab

Where I live in the Bay Area, there is no machine shop that will do a valve job on the heads for $500. It would be $2,000 minimum.
Shipping that short block from Atlanta to San Francisco is $500 at least, could be more.
Don't forget oil, gear oil, coolant, brake fluid, etc... and filters.

I don't see it for less than 10K, maybe 11K.

Porschetech3

Nickies DIY for M96/01 /02 /04 years 99-2001

Nickies for 3.4 3.6 3.8 from LN $4995.00 (includes pistons/pins/rings/clips)
#1364363-M9601SET complete gasket set/bolts ect. from AutohausAZ $475.25
996-105-253-00 Vario cam guides from Auto Atlanta $21.66 need 2 sets
Part# 000-043-204-35-M258 Loctite 5900 from Pelican parts $14.00

Part # 996-105-170-53-M48 Iwis cam to cam chain From Pelican Parts $21.00 x2
Part# 996-105-177-53-M48 Iwis long chain from Pelican parts $56.50 x2
Part# 996-105-171-55-INT Iwis IMS chain from Pelican $28.00
Part# 996-105-175-52-M260 chain guide (primary)From Pelican parts $28.25 x2
Part# 996-105-173-52-M260 chain guide (secondary) from Pelican parts $28.50 x2
Part# 996-105-165-55-M100 IMS chain rail from Pelican parts $38.25
Part# 996-105-166-51-M100 IMS guide from Pelican parts $46.25
Part# 10-0124-125-M3020 LN/RND IMSB from Pelican parts $733.50
Part# 996-101-115-62-M100 carrier bolts from Pelican parts $6.25 x14
Part# 996-101-205-10-M100 main bearings from Pelican $ 8.25 x14
Part# 996-103-121-62-M100 rod bearings from Pelican $8.25 x12
Part# 996-101-129-52-M100 thrust bearing from Pelican $14.50 x2
Part# 900-041-004-01-OEM IMS chain guide clip $1.00
Part# 204-6301 Rod bolts from ARP $222.69
$7196.76 parts Total
$500.00 head service
$ 7696.76 + your labor

Not much more than the Factory short block, this is the way to go if you have the Skilz !!!!

pdxmotorhead

Heads truly will depend on the condition,, despite all the myth and legend, not all Porsche bits are special..
Doing the heads on a 911 is no harder than Subaru heads.. boxer is a boxer especially with overhead cams.

The price can go high,, new valves will drive it up, if any seats are bad.. Guides etc..
but I have access to the tools so for that bit its parts only.. keeping this as a budget
estimate yea should allow for the higher end and hopefully get lucky.

I'm also not going to try and replicate a FSI engine,, I tip my hat to their experience and ability to optimize end to end..

AnthonyGS

I’d consider adding having a machine shop check the crank and rods for the nickies option. Both need to be checked for size, concentricity, etc. Assuming you can reuse them might be okay, but I’d rather be certain. Having the rods prepped for ARP rod bolts might be reasonable too. 7,000 rpm isn’t a joke.

pdxmotorhead

Definitely,, luckily that's not a real expensive thing to do.
Dropping all the cams in a "Cam DR " to check they are straight as well.
Same with the IMS.
I'd prob end up paying 2 hours to one of the shops locally to check for straight and magneflux the crank.

Porschetech3

My cylinder head guy (the largest cylinder head service in the state, that I have known for decades) does my 996 heads for $200 bucks each, he has even fixed the crack on mine 12 years ago when I first got it,(still going strong). and has since fixed a half dozen more for people that I commissioned. Some cylinder head shops will insist on new springs, guides, without even checking them to see if the guides are worn, or if the spring pressure is weak. I guess checking spring pressure and checking guide wear doesn't pay as well ..

Your right, my cylinder head guy didn't bat an eye when I brought in the Porsche m96 heads even though he had never seen one, and I showed him the crack I wanted fixed..lol

pdxmotorhead

I've had a 4" hole in the side of a aluminum block that went into a cylinder filled and welded and
sleeved, it did another 3 seasons till a new rookie driver decided that 10K rpm's just wasn't good enough..

Aluminum is amazing ..

Porschetech3

The m96 rods are forged powdered metal "cracked" rods(cracked at the parting line to create a unique positive mating surface), there is no reconditioning/prepping them. Looking at the old bearing will tell you all you need to know, if any question or doubt, toss them and put in a good set of H-beam 4340 rods

jimham968

Got a question. Rather than use an M96/03 short block could you use an 997S M97 3.8 short block to get a displacement increase?

carlvs

I posted a spread sheet of the cost to rebuild my M96 3.4 engine in my coolant intermix post. It falls inline with the parts quoted above. My engine had a new AOS and LN Engeneering IMS bearing already done. I did have the added cost of repairing the cracked cylinder head. I was also fortunate that I found a set of cases on eBay that were Nikasil plated and came with pistons. About $2100.00.

The total came to $7,700.00

Here is a link to the spreadsheet. http://www.ez-bizwebs.com/3.4/images/Spreadsheet/Porsche996_EngineRebuild2.pdf

soverystout

I would replace all of the valve seats as part of the refurb just due to that being a mode of failure.