Porsche 996 Carrera: Zweite Motorinstandsetzung, diesmal solide durch Albert Motorsport
Scope of Work:
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Transport the vehicle from Slovenia to Albert Motorsport
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Inspect and assess the engine damage, prepare a cost estimate
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Remove engine and transmission, completely disassemble the engine due to damage
Extent of Damage:
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Severe oil consumption
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Significant coolant leakage through the head gaskets into the exhaust
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Extensive damage and assembly errors in the engine
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Crankshaft bearings were installed incorrectly and are bent
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The crankshaft is now damaged due to this glaring mistake!
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Exhaust mount is broken
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Crankshaft damaged at the flywheel contact surfaces
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Intermediate shaft damaged at the contact surfaces
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Pistons have incorrect clearance in the cylinders
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Piston rings have incorrect end gap for use in steel cylinders
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Piston protrusion is too high!
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Incorrect cylinder head gaskets used, too thick!
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Neither the engine block nor the cylinder heads have flat sealing surfaces
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Unbelievable negligence during assembly
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Chain guides were not replaced and are defective
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Sealing surfaces for the crankshaft seals were not machined
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Intermediate shaft thrust surface damaged due to faulty assembly
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Crankshaft seal surfaces were roughly filed by hand
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All crankshaft bearings are defective
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Dirt during assembly caused scoring in fits
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Overall, a case of appalling negligence!
Repair Process:
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Transport the vehicle from Slovenia to Albert Motorsport
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Remove engine and transmission, completely disassemble the engine due to damage
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Thoroughly clean all parts and inspect for damage and defects
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Prepare a cost estimate
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Consult with customer, repair order confirmed by AMS
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Damaged parts will be kept for evidence
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Clean engine block using shot peening and densify surface
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Rework cylinder heads
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Rework valve train
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