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02-22-2012, 11:27 PM #1
Two More 3.9L Projects Underway @ Shark Werks
It's been a while since we posted an update about our long term projects so I thought I'd start another thread.
While I can't show everything we're working on, there's a new 3.9L 997 GT3 build that's unique. And on the lift she goes!
This car came in with approx 58,000 miles, mostly used as a track car and already equipped with a load of goodies: EVOMSit software, exhaust, full Ohlins 3-way coil-over setup, these HRE wheels, Guard LSD, roll cage, racing seats and all the gadgets for timing/video on track days. We are doing the 3.9L including a bottom end refresh and valve job, and the coolant leak fix.
Notice the HRE P40 wheels and wheel studs.
A short time later, James has reached a milestone in surgery:
With this kind of mileage, it's expected to have a little dirt and oil on the exterior.
It looks nice from this angle:
But a lot smaller from here:
A previous shop had performed a fix which was intended to seal the coolant pipes in place, by welding. Unfortunately the welds did not last or were not up to the job and therefore leaked over time. We now have to replace a couple coolant housings and fix these troublesome lines in place using a screw and loctite. More info on our solution is available here.
And a bit dirtier once the intake is removed:
The valve covers are removed:
More sludge removal and more parts coming off:
Now we're getting somewhere, with the pistons in plain sight.
02-22-2012, 11:27 PM #2
The case prior to splitting:
And after, showing the crankshaft and oil pump.
And here we are giving the parts a bubble bath in our parts cleaner. This is quite a long process considering all the components to this engine. But it does ensure everything is clean and seals like new when reassembled.
While the parts soak, James turns his attention to this 2012 Turbo, which is receiving our exhaust upgrade:
Here's a video in case you were wondering how a new Turbo can sound compared to a GT3
Shark Werks 997.2 Twin Turbo Exhaust System - YouTube
Before we get back to work, a GT3RS comes in for some RSS suspension goodies and EVOMSit software, as well as our GT3 bypass exhaust.
Back to our big project, we can take a peak at the valves:
Since the car has higher mileage than we've seen and it's been driven very hard, it requires more attention on the internal bits for freshening up than a typical build. New connecting rod bearings and bolts are being used, and the heads are being worked on and I'll have some "after" pictures soon.
The results of the cleaning process:
Ready for new rod bearings.
The case is reassembled with new seals and the next step is pistons, which will have to wait for another post.
And as we're buttoning up this project, another is on its way. A white 3.9L 997 GT3 much like this one, and this time the car comes from Florida; its owner is also shooting for Ohlins and a handful of other upgrades...
02-23-2012, 12:17 PM #3
Lovely!! nice work, shop and cars!
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02-23-2012, 10:22 PM #4
Looks good!! Cant wait to see the rest of the build!Ian
06 330i For Sale (looking for 135i, X5)
02-23-2012, 10:31 PM #5
I jizzed in my pants, twice. Loved looking at the step by step pics. One of the best shops around if not "The Best".
02-23-2012, 11:08 PM #6
02-28-2012, 08:12 PM #7
With the 50k+ miles, the valve guides have excessive movement, especially on the exhaust side, and since the stems are only 6mm, we opted for a refresh of the head. New valve springs and guides, along with a little clean-up
02-29-2012, 10:12 PM #8
On the home stretch now. As stated above with cars with high track miles when doing an engine build it would be wise to have the heads refreshed. This includes a nice jet wash, clean, polish and resurface (cylinder heads will have slightly higher compression), resurface the intake and exhaust valves and replace the intake and exhaust guides with honing for proper oil clearance, cutting of intake and exhaust seats. One thing you can also do is use manganese bronze guides that will last longer than factory:
Re-assembly continues with our 3.9L pistons, liners and our ring package:
One side in:
Assembly with the water jackets and cylinder package is a precision process requiring some factory tools as well as our own:
We also use our non-factory head gasket which is set up for the larger bore:
Installed and with our larger bore we use steel liners for strength:
On go the refreshed heads (with new springs too):
And assembled (there's a special torquing procedure here too):
Seal this thing and leave to dry over-night:
Almost ready to start installing the lifters:
In they go:
And the SharkWerks spec cam shafts are next:
02-29-2012, 11:04 PM #9
03-06-2012, 05:49 PM #10
Setting up the timing blocks:
Timing the cam shafts:
The intake manifold, wiring harness and all aux. components installed back on the engine:
The transmission is installed with the LWF and clutch upgrade (a Guard LSD is also fitted):
Back into the engine compartment:
All the fluids are put in as well as the intake:
We did say this project was a track car and hence the Shark Werks Track Exhaust is installed:
From the bottom that's now a very nice clean 3.9L engine ready to make some noise!
A look at that 3-Way Ohlins set up:
Two racing seasons later on the RSS links and still going strong!
With her HRE P40 Wheels on she's ready to be broken in:
She'll be off to TC Design for one of their slick roll cages as well as coming back for a factory RS tail: