Today I started cleaning the next round of parts. Here they are.

http://i983.photobucket.com/albums/a...psqune6lzx.jpg

I focused mostly on the oil pan for now. Nasty starting point.

http://i983.photobucket.com/albums/a...pswr3jbzqn.jpg

I think the oil pan was removed at some point and reinstalled with a lot of sealant.

http://i983.photobucket.com/albums/a...pseixcnsgc.jpg

A lot of sealant was necessary because it looks like someone cleaned it with a grinding wheel in the past. Sweet. We'll have to see how it seals for me.

http://i983.photobucket.com/albums/a...ps5mppykb0.jpg

Looking a little better.

http://i983.photobucket.com/albums/a...psckekbzhg.jpg

I think I'm going to take a break for a few days. Happy Holidays everyone!

Yum! Gotta love that 5900 generously applied! Your sump pickup didn't look clogged so I guess most of the 5900 was still attached to the pan face and you scraped it off?

The stock oil pan actually has a burled face to it that ripples under a scraper knife, I assume for adhesion although it IS made in Belgium... Maybe that's what you noticed?

Enjoy your time off. Funny, with my time off I hope to do what you're doing when you're not taking time off... Where does all the time go?!?!?!?!

There was a little bit of 5900 in the pickup as well. I had done some cleaning on that before taking the photo. Luckily, most of the gobs of 5900 stuck to the pan and have now been removed.

Yep, I know what you mean about the ripples on the sealing surface of the pan. My photo doesn't how it, but in some areas those seem to have been ground off, that's what had me worried.

Cylinder Heads, etc
 

Mihnea,
To try and keep up with your project I've been reading my $8 Ebay shop manual. They go so far as to want the crank shaft pulley seal installed deeper than the old one to ensure the new seal rides on a fresh spot on the crankshaft.

What do you plan to do with the cylinder heads? In distant past I would leak check the valves sealing with gasoline. At your mileage I'd guess your valve stem seals are toast and probably the valve guides too. I've read that the 986 valve guides actually last longer than the 9A1 valve guides because the 986 ones are longer.

Anyway enjoy your time off. I'll be playing with my new Sears ATV lift that Santa brought me.

We came back from visiting the grand kids in Atlanta. The Porsche sign is off the old headquarters building on Hammond Drive in preparation for the move to the new HQ at what used to be the Ford Taurus plant I believe. Our new Cayenne diesel returned a calculated 36.8 MPG and is still breaking in. I'm happy with that.

Regards,

Rob

Mihnea, Enjoy seeing the progress and impressive attention to detail!
V/R
Hugh A.

Rob - That's awesome news regarding your new Cayenne diesel. My tow vehicle for the Cayman is my wife's DD, which is an 08 Cayenne S. The V8 tows nicely, but MPGs are appalling. I'm looking forward to a used diesel when the prices come down a bit.

I'm planning on leaving the valves (and heads in general) alone. The wear seemed very reasonable and I wasn't burning any oil, so I'm not going to touch them. I will do some valve cleaning and the gasoline test (or similar) soon.

Make sure to post a link - or better yet - a thread here when you get going on the Cayman.


Hugh - Thanks a lot!

There is a little progress to report today. I finished cleaning and assembling the oil sump plate. Here it is cleaned up, ready for installation.

http://i983.photobucket.com/albums/a...psmrl3y0vd.jpg
http://i983.photobucket.com/albums/a...psoiqnbrid.jpg
http://i983.photobucket.com/albums/a...psdt77sjwr.jpg

Then it was time to install the in-sump AOSs and oil pick-up tube.

http://i983.photobucket.com/albums/a...psyirnmoye.jpg

Here is the bead of Drei Bond, masterfully placed by Ion.

http://i983.photobucket.com/albums/a...psxdzatjbn.jpg

And done.

http://i983.photobucket.com/albums/a...psjljohmlx.jpg

Next, I installed the chain ramps. Old and new to compare the wear.

http://i983.photobucket.com/albums/a...pskd0itiay.jpg
http://i983.photobucket.com/albums/a...psv1volxxz.jpg
http://i983.photobucket.com/albums/a...psagtcpik5.jpg

Chain ramps and chain ramp bolts ready for installation. I cleaned, greased the bolts, and replaced the o-rings.

http://i983.photobucket.com/albums/a...psi77mhctu.jpg

Chain ramps in place on both banks.

http://i983.photobucket.com/albums/a...psjnlyvpsh.jpg
http://i983.photobucket.com/albums/a...psqrsuhgz6.jpg

To finish up the short block, I need to install the water housing and oil pump, but I'm missing one of the metal gaskets for the water housing. While the part is making its way here, I will go back to cleaning parts. It's time to start working on the heads.

Mihnea,
OK on your heads, my thinking was that all the carbon on your piston tops might have come from the valve stem seals since your rings and cylinder bores were in great shape. I don't have an immediate project for the Cayman but am anticipating a clutch job after this upcoming season of AX is done.

I did try to buy a used diesel Cayenne but they hold their value quite so well that for a few more pence we got a new one locally. This will be my wife's DD also. The towing capacity is quite robust which will come in handy towing the Habitat electrical trailer to the different job sites. Hard to believe the diesel is now the base model Cayenne but that works for me and it seems to get better mileage than the eHybrid. My son told me I'm the only Cayenne owner obsessed with fuel mileage. This is the same son who told me I was too old to have a mid life crisis when I bought the Cayman at age 64....

Obligatory question: is your water pump 4 years or older?

Happy New Year

Rob

The water pump is newer than 4 years (probably 1 or 2) as I've been replacing belts, water pumps, spark plugs, etc., etc. as I piled on the miles.

It's never too late (or too early for that matter) to buy a Cayman, if you're a person who enjoys driving. By the looks of things, a gen 1 Cayman like ours can be had for Toyota Camry money or cheaper. If you can do your own maintenance, than the ownership cost is reasonable too and I would argue that the Cayman is a better car...:)

I'm always surprised by how many folks make the (wrong) assumption that owning a Porsche is not feasible for the average person.

Looking great! Happy new year, all.