Porsche 997 Carrera upgrade to 4.2 liter by Albert Motorsport

It's a long drive through wintry Germany before I stand in front of our new customer's house.

From there I will bring his beautiful Porsche 997 Carrera in GT3 look to our company.

Our new customer had inquired about the best repair method for his engine damage on the Internet,

and then decided on our company as a repair shop. During the telephone calls in advance and during

upon collection, we had discussed the core of the most important points of the upcoming work.

Below I list the repair process in words and pictures, so that our customer

and you, dear readers, can find out about the execution of our work.

If you have any questions about the technology, we are at your disposal.

  1. Collection of the vehicle at the customer's home
  2. Delivery of the vehicle to our company
  3. Waiting time until the job can be executed
  4. Take the vehicle from the waiting room to the workshop on the lift
  5. Remove all underbody panels
  6. Drain all liquids (oil - cooling water - air conditioning etc.)
  7. Engine and transmission removal
  8. Dismantle the engine and mount it on an assembly stand
  9. Removal of the intake system
  10. Removal of the injection system, the intake manifold and surrounding parts
  11. Removal of all cables and lines, hoses etc.
  12. Removing the cylinder heads with camshafts, chains, etc.
  13. Dismantling the engine body with dismantling of the pistons
  14. Removal of the crankshaft, connecting rod, intermediate shaft
  15. Inspection of all parts with identification of acute defects
  16. Inquiry with the manufacturer and supplier about the ability to deliver all components
  17. Contacting Sattler regarding the availability of the Alcantara equipment
  18. Contact our exhaust manufacturer to create a mid-exhaust system
  19. Current status:
  20. Preparation of a cost estimate for all options requested by the customer
  21. Probing the ability to deliver and delivery times for all relevant conversion parts
  22. Scheduling with our milling center to mill out the engine block
  23. Provision of all materials for the planned engine construction to 4.2 liters
  24. Termination of the production of forged pistons for the 4.2 liter engine variant
  25. Termination of the production of the piston rings for the 4.2 liter engine variant
  26. Placing an order according to a cost estimate as follows:
  27. Conversion of the existing engine to an Albert - Motorsport 4.2 liter variant with
    forged pistons and standard compression while maintaining the electronic
    parameters of the engine via the broadband lambda probe.
  28. Installation of a large intake system with a large throttle valve
  29. Production and assembly of a stainless steel sports exhaust system, analogous to the 997 GT3 RS with center exit.
  30. Installation and painting of a Porsche 997 GT3 RS 3.8 - 4.0 liter rear spoiler gluing of a large PORSCHE
  31. Lettering on the spoiler sheet painted in white analogous to the Porsche 997 GT3 Cup - omitting the series
  32. Lettering on the tailgate.
  33. Installation of an LED daytime running light (alternative accessories according to customer requirements)
  34. Solid assembly / reinforcement of the driver's seat, which is still wobbly at the moment
  35. Disassembly of the standard rear spoiler
  36. Adaptation and assembly of the new 997 GT3 RS rear spoiler
  37. Dismantling the driver's seat - repairing the torn-out threaded sleeve in the laminate with epoxy
  38. Checking and modifying the seat console
  39. Forged piston blanks are now made for us, the announced delivery time is approx. 4 - 5 weeks
  40. High-strength piston rings for piston and cylinder gauge blocks for our graphite cylinders are manufactured.
  41. The announced delivery time is approx. 4 - 5 weeks
  42. A center exhaust made of stainless steel with pipes with a large cross-section analogous to the 997 GT3 RS is made.
  43. Received the order confirmation for the piston forging blanks
  44. Received the order confirmation for the piston rings and gudgeon pins
  45. Bringing the customized rear spoiler to our painter
  46. Production of graphite cylinder blanks for the planned engine conversion
  47. Free turning of the motor housing
  48. Milling work on the inside of the motor housing
  49. Arrival of the first Porsche tuning parts - complete X51 intake system
  50. Arrival of the graphite cylinder blanks
  51. Notification to the customer that the forging blanks have not yet been delivered.
  52. Commitment to delivery of the piston - forged blanks by Thursday / Friday
  53. Commitment to delivery of the piston rings for the notified cylinder size by Monday
  54. Arrival of the pistons and piston rings
  55. Fine machining of the pistons and piston rings to the future cylinder - final dimensions
  56. Coating of the piston skirts with solid graphite
  57. Drilling out and fine-tuning of the connecting rods to the final size of the gudgeon pin
  58. Free turning and milling of the cylinder seats in both halves of the engine housing
  59. Rough pre-turning of the cylinder blanks
  60. Precision turning of the cylinder blanks to fit and glue dimensions in the engine block
  61. Pressing and gluing the cylinder blanks into the engine block halves
  62. Pre-bore the cylinders to a rough piston size
  63. Precision boring of the cylinders to 1/10 mm of the final piston size
  64. Fine grinding of the engine block halves in the area of the
  65. cylinder head gaskets
  66. Pre-honing of the inner cylinder surfaces
  67. Fine honing of the inner cylinder surfaces to an accuracy of 1/100 mm
  68. Coating of piston skirts with solid graphite
  69. Turning out the piston pin bearings in the connecting rods
  70. Production of new bearing bushes from high-strength bronze for connecting rod eyes
  71. Reaming the gudgeon pin bearings to 1/100 mm fitting accuracy to the gudgeon pins
  72. Previous angling of the connecting rods at 90° to the crankshaft
  73. Fine - polishing of the crankshaft bearings
  74. Measuring and adjusting the KW bearing fits with Plastilube
  75. Assembly of the engine block half in the engine stand
  76. Start assembling the engine
  77. Assembling the crankcase
  78. Installation of the crankshaft and connecting rod
  79. Installation of the intermediate shaft
  80. Installation of the pistons and piston rings
  81. Written customer contact regarding completion and technical questions
  82. Assembling the crankcase and cylinder heads
  83. Takeover of the rear spoiler from the painter with subsequent assembly
  84. Installation of the timing chains and other internals of the engine
  85. Installation of the complete valve train and camshafts
  86. Precise timing adjustment
  87. Performing a Cylinder - Leakage Test. Result = 100% OK, so perfect!
  88. Installation of the surrounding motor and control components
  89. Installation of the new large intake system with adjustment of all surrounding components
  90. Assembly of the engine with preparation for installation
  91. Installation of the exhaust bracket and installation of the cat system and fan manifold system
  92. Production of further image material for the documentation
  93. First test run without rear silencers, which unfortunately are still behind schedule
  94. Notification from UPS that the mufflers were lost in transit
  95. Notification from the manufacturer that, according to UPS, the search query has not been successful to date
  96. Consultation with the exhaust - manufacturer that, if the dampers until next Wednesday
  97. 03/28/18 are not in our house, a new system and new dampers are made for us.
  98. Installation of the painted rear spoiler
  99. Contacting the foil suppliers to obtain an identical foil for the spoiler lettering.
  100. Renewed correspondence with the exhaust manufacturer and UPS, the rear silencer has not yet been found
  101. UPS replaces the loss - damage at the earliest after a waiting period of 8 working days
  102. Consultation - contacting our manufacturer when the new system to be built is available for us
  103. Agreement with the manufacturer: "On Tuesday after XX.XX.XXXX we will send back the parts of the system that have already been delivered,
  104. if the lost system has not been found - a new one will be made to match it - as soon as possible
  105. Rear silencer made for the vehicle"
  106. E-mail - contact with the customer, answering his questions, notification that if the facility until Tuesday after
  107. XX:XX:XXXX is not with us, a completely new rear silencer system will be built for him at UPS expense.
  108. UPS - recall on XX.XX.XXXX, the exhaust system is found. It will now be sent to us by express,
  109. so that she is in our company on Tuesday.
  110. Arrival of the exhaust system
  111. Immediate installation of the exhaust system - test run - leak test etc.
  112. Short test drive - result in a slight jerking in the transition area (partial load) Electronic check of all sensors and electronic components: result camshaft sensor left engine bank stiff. Installed used part - result - jerking has disappeared. New part ordered for customer.
  113. Color fan from the foil - supplier received - suitable foil ordered - rest of the foil for the customer
  114. Driver's seat post-laminated with epoxy. Seat console re-attached - marginal slight play in the seat rail, wobbling in the driver's seat eliminated.
  115. Test drive done with a used sensor - result: the car runs fantastic, just like a GT3!
  116. Appointment made for the dynamometer - sensor from Porsche still in arrears
  117. Dynamometer - Perform test with used camshaft sensor. Appointment announced.
  118. Email - consultation with the customer - "preliminary fixed" delivery date notified.
  119. Premature bringing of the vehicle to the dynamometer wg. Failure of another customer
  120. Lashing down the vehicle on the dynamometer. Running off all parameters - control - adjustment - correction of the motor - parameters if necessary.
  121. Departing all parameters - performance test - result ... yesss!!
  122. Long test drive done, the car runs fantastic, pulls through like a GT3 and accelerates completely unleashed from lowest revs, high.
  123. A real fun machine with super sound!
  124. A defect is presented to us, namely, in our opinion, the "breakaway moment" of the starter is too low,
  125. the starter does not turn powerful enough. Let's take a closer look at that.
  126. Result: battery has undervoltage, when starting - the "volt range" pulls down to below 9 volts.
  127. The starter has too high a current consumption and a
  128. Mehr zu diesem AusgangstextFür weitere Übersetzungsinformationen ist ein Ausgangstext erforderlich
  129. Feedback geben
  130. Seitenleisten
  131. Verlauf
  132. Gespeichert
  133. Etwas beitragen
  134. Zeichenbeschränkung: 5.000. Du kannst mithilfe der Pfeile weiter übersetzen.
  135. too little power, therefore AT - built-in starter.
  136. The film has arrived, the rear spoiler is immediately pasted according to customer requirements.
  137. Final exam and final test drive, this test drive was passed perfectly and without any complaints

We are happy to give our customer a very well running sports car

to be able to deliver, with which he can go on a 997 GT3 hunt in the future!

Jürgen Albert

master mechanic

Team Albert Motorsport

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