2001 Porsche 996 LS1 Conversion Thread by 1dirtyZ

12 minute(s) of a 536 minute read

a few more pics of my progress

guage pod still needs a bit of tweaking
:



better pics of the charge pipes and BOV (ignore the bunched up wiring on the right side ,,, it will be cleaned up ) :







and I finally connected the AC signal wire

time to charge It

11-3-2015

will do

so I took the car home to drive it around and break it in , sadly the fuel pressure issue is not fixed , fuel pressure still drops at high loads .

and since I ruled out the fuel filter being restrictive , I'm now leaning towards fuel cavitation just before the pump.

I'm thinking that since the pump is sitting above the tank , it might be struggling to suck the fuel out of the tank and thus causing it to "boil" and bubble , which in turn leads to the pressure dropping .

the problem is that I have seen some time ago the pump in this exact location on a yellow RSR racing Porsche , which is confusing me right now .

and doing a bit more research , I seem to need around 375 LPH ( comes out to 600 Lbs/hr or 100 Gal/Hr )of fuel to cover my needs on this setup, and looking at the flow charts on the web it seems the 044 pump can only provide somewhere in the neighborhood of 250 -270 LPH at 60-70 psi of pressure ,,, so this might be the issue I'm facing right now.

so I guess I should give the new AEM 380 pump a try since it fits in the same place as the bosch and takes the same fittings.

so ,,, next up is swapping the fuel pump and seeing what this will do

11-22-2015

time for an update

finally got to put it back on the dyno again.
first off the AEM pump was kinda doing its thing , fuel pressure never dropped below 55 psi , although it needed to be something around 70psi at WOT. I'm not worried about that now since it still has that restrictive check valve in the outlet, I'm sure the pressure will be ok as soon as I remove that valve and replace it with a straight through fitting.

well on to the stuff you guys want to know ,,, but before that I just wanted to let you know I didn't take the car to get the rear alignment yet

so what did it make on the dyno at 14 psi and pump gas???



not to shabby for a daily driver off course there has to be some bad news in there ,,,, apparently the stock clutch has its limits I guess , some where around 600whp or less , since the dyno graph was showing horse power dropping off top end while boost was also dropping , couple that with how fast the engine revs to the rev limiter and the face that the car made more horse power when the it was dialed down ( less timing and richer AFR ) , which means the clutch was holding at lower hp levels but when turned up it slipped.

here is a graph I managed to take of one of the runs ; boost is at the bottom :




all of that was confirmed when I stuck the front driveshaft back in to the car and took it for a spin , the added load immediately showed how bad the clutch was spinning - at around 4500 rpm in 4th the rpm would shoot up .
I couldn't notice it when it was 2wd because the car would loose traction before the clutchwould slip and there wouldn't be much load on it then.


any how I'm just giddy with joy right now , knowing this thing has 700+ AWDRWHP in it as soon as I iron out all the bugs . it drives great and pulls in every gear - including 6th ! I just can't wait to get this thing done so I can start picking on some other cars

so next up on the to do list :

- install a better clutch
- remove the one-way valve in the fuel pump
- rear alignment
- new tires
- retune and maybe do a race gas tune
- charge the AC system

2-7-2016

I guess its time for an update ,,,
I did get around to changing the clutch to the one I got from Kennedy engineering. at first I was a bit skeptical thinking that the stock clutch was a twin disk setup ( don't know why I was thinking that ) , but when I took the old one out I found out it was a single disk unit ,,, which meant I felt a bit more comfortable putting the Kennedy unit in since they said that it should hold quite a bit more than the stocker.

I also managed to fix the driver side headlight , It had a bad ballast/ transformer which I just changed ,,,, and now I have two working headlights, all be it one yellowish in color and the other more blue - I changed the bulb a while back thinking It was the culprit and never knew what the original color was

and for some reason the dash lights are all on now . it seems in the re-install process I may have forgotten to connect a ground or something. and my rpm gauge doesn't work either due to a faulty sensor. so if anyone would like to give me suggestions why my gauge lights are not working as well as my oil pressure gauge and horn please chime in

so after all that I put a few miles on the clutch to brake it in and then I took the front driveshaft off to take the car to the dyno .

happy to say I overshot my goals

off course this brought in a new set of issues

first off I don't want it to be that powerful ( can't believe I'm saying that ! ) , 18 psi and climbing is a bit high for what I want . I have to bring it down to a more pump gas friendly 15-16 psi , this way I save the heads and gaskets from getting lifted , plus gives me a good buffer timing wise to take into account varying grades of pump gas.

the other issue is at this power level it was at the limit of the fuel system if not over it , fuelpressure would climb with boost then drop down to 50 psi at the top end , and my injectors were at - get this- %150 duty cycle !!

so now I have to add another fuel pump in parallel to the one already there and get a set of bigger injectors ( I think the ones on there are somewhere between 60 to 75 lbs/hr - not sure since they were taken off my mustang ) , I'm thinking anything over 85 lbs/hr should do the trick .

other than that I'm a happy camper

the plan now is to loosen the adjustment rods on the waste gates to turn the boost down a bit , install the second pump and plumb it , and mess with the wiring to see why I have all the dash lights on

5-16-2016

quick update time ; well nothing much going on , I loosened up the actuators on the turbos' waste gates to try to turn the boost down a bit , still need to verify it . another thing I noticed is I was getting a misfire lately , and once I started investigating the causes it found two issues: the first is the number 8 spark plug is being coated with oil, I'm assuming the valve stem seal is going bad , but I have to double check with a compression and leak down check just to make sure.
the other issue I found out is when the car was idling I did the "jiggle " test and the car actually died when I moved the harness. so now I have an electrical issue with the harness I have to fix.
so now that the harness needs to be checked or fixed ,,, I decided this was enough reason to swap it out for a Holley harness and ECU  so I ordered the harness , ecu and injectors . This way I should be able to tune the car easily and log stuff and have the benefit of a self-learning ecu .

I also had a cut front cv boot to fix ,,,, so I did , and while I was under there I swapped both sides as well as the front wheel bearings.
I also I decided it was time to fix that annoying weak starter that seemed to lose all power once it got hot. So I ordered on a while back and once I came around to installing it the shift arm mechanism on the transmission bumps in to the rear of it, you can see why in the next pic; for some reason this starter is about an inch longer.

And here you can see what hits the back of the starter , it’s the round weight thing on the top of the shift linkage :

And while the car was on the lift I kinda noticed a small problem

But luckily I just bought a set of mickey Thompson 305/35-18 drag radials last week ,,, geuss it was racer’s intuition
And here is how they look side by side and what not :

And here they are all mounted up and pretty:

I’ll also be changing the front tires too , I will be going with a 245/40-18 fronts to match the added height the rears have . the good thing about these new sizes is that they fill the wheelwell nicely , and give me a slightly taller gear ratio which should make the car even more fun to drive around .

So next up on the to do list is :
-swapping the front tires
-waiting for the new starter to show up and install it
-Change the headlight bulbs ( right now the color is off on both sides)
-Swap out the old valve seals ( that should be fun )
-Install the holley stuff once it gets here and wire it.