2001 Porsche 996 LS1 Conversion Thread by 1dirtyZ

15 minute(s) of a 536 minute read

not much to report , i got the pan on the new engine , i still need to get the oil cooler adapter on the pan and ready to be plumbed tot he existing cooler. i also need to find a spot to mount the porsche oil pressure sensor on the pan. i'm thinking on the little bulge thingy on top of the oil filter .

other than that , just been driving the car and beating on it , trying to get any issues to show right now. also a few new parts showed up 

the new tail lights and bumperetts showed up , i should install them sometime soon :

and another little box showed up from comp turbos , the new t3 internal wastegated oil less units were nicely packaged in

now that they are here , i have to start mocking them up , but the thing is i have to take the header and mufflers off one side of the car and install the new manifold and kinda mock up where i want it to sit and have it connect to the current exhaust . i'm trying to do this with as little down time as i can.

9-7-2012

thanks for the compliments guys ,

and marky , thanks for the offer , but i don't think its the pad wear indicator because i'm pretty sure the pads had quite some beef left in them i'm thinking maybe a sensor or sensor plug in the front hubs i guess or something beacuse ( and i could be totally wrong here) i noticed that there is a 10 MPH difference in what the analaoh spedometer is pointing at and what the digital readout is showing . i know on some cars the speed signal is taken from one or both the abs sensors on the hubs , which is the case in this car .

i guess i'll just have to take the wheels off and double check again .

no marky if you are reading this , do you know which sensors ( location ) are the ones responsible for the speedometer signal?

and in other news , i took the car to the track for another round of beating / testing

ended up with a personal best of 12.65 @ 109 !! i didn't change a thing , but i think the cooler temps might have helped

here is the vid of the run , you can see the car actually spins a bit when launching ( it only got a 1.8 sixty ) , i guess it could use a rear alignment to help out a bit.

man i'm loving this car more everyday

9-9-2012

thanks alii !!
you da man!

i put the thing on the lift last night , and started poking around and what do i find?? well for starters the front brake ware sensors and speed/abs sensors were plugged in each other's hole , so that explaines the speedo error and the abs/brake light .
also found out that i have a cut CV boot up front that needs to be changed soon i guess. guess i never did look at the front end well when i was assembeling the car

moving on back , i found out that the passenger side CV allen bolts where all loose! so a quick cleaning and a bunch of red loctite and that was cured.

after that i took a closer look at turbo placement , and to my surprise using LS3 vette manifolds will actually place the turbos a bit higher that what i need , so i will have to make an extension to lower the turbos a bit down . the other good thing it that if i lower them the exhaust housing will fall exactly in line with the current exaust with minimal fab work needed

so next up is making a jig to hold the mufflers in place and them remove the headers and install the manifolds and start fabbing the turbo piping to connect the two .

i also have to look into the water cooling for the turbos, i was thinking of running a hose from each steam vent ( on the back of each head ) to the turbo on each side and then back to the coolant resv.

i'm also contemplating relocating the electric water pump to somewhere under the car ( to clean up the engine compartment ) but i'll have to look at this idea when i'm under the car again

10-13-2012

loool, any time buddy

well some news to report

took it out to the local street racing spot for some fun ,,, i mean testing

managed to race a Grand cherokee SRT8 two times from a dig,,,,, man i really thought they would be faster

also had a funny encounter with a 5th gen camaro that went like this :

me : wanna race ?
him : whats it got ?? is it a GT3??
me : naaah , its just athe GT wing , nothing much else .
him : man your car is fast , its the best engines that germans produce .

..... please keep in mind that this conversation was taking place while my car was ideling next to him , and loping , and slightly surging ,,,,,, just like a v8 would


me : its stockish ,,,,, it only has a cam .....
him : lets do it from a roll .
me : cool ,,,,

we roll ,,,, i win


the stupid part is after the race the guy pulls up next to me and tells me : i told you german cars are quick even stock !

i just giggle and drive off ,,,,, i think he might of been deaf

and then i race a c6 with a buch of bolt ons , we do it from a roll and we are very close , he slight;ly jumps on me when he shifts or when i do ( stupid close ratio trans ) ,,, and then i hear the rattling noise ,,,,,
so i pull over and luckily it was just the serp. belt that decided to shred itself
there was a little left of it that i managed to slip back on the pullies and decided to drive it home , which it did nicley

total damage :
1 rpm sensor ( looks beat up , yet to test it) and bracket .
2 serpentine belt

and thats about it

sorry for the long storry , but i had so much fun that night i just had to share

11-7-2012

update time

so after the misshap that happened in the last "testing session" the car basically sat in the home garage up untill a few days ago. thats untill i drove it to the shop and decided to swap the belt and check for damage. well thats what i was planning on doing atleast

so on goes the car on the lift and i poke around under there to see what i can find, luckily nothing bad ; just an rpm sensor with a bent bracket and shreds of belt everywhere .

then i thought why not mess with the PS system ,,, i thought sine i drove the car quite a bit with the pump disconnected , the constant cycling of the steering should have forced the air out of the system ,,, so just in case and since the car was on the lift i cycled the steering a few times just for good measure , and then it dawned on me : i never vaccume filled the PS system! ( or atleast i don't remeber doing so )

soooo, since i had the car on the lift , and the vaccume filling gizmo was close by i decided to give it a shot. and what do you know ; as soon as i do so i hear a "burp" from the steering reserv so just for good measure i cycle the steering manually again and top off the fluid (incase you are wondering , i'm not using pentosin, instead i went with regular dexIII GM tranny fluid )
so now comes the moment of truth : i slap the long belt on there and start the car and guess what ! no whining or bubles

off course i still have to verify that it works after i put the car on the ground and place the steering system under load.

so now i'm happy i got that figured uot ,,,, and since i had the car on the lift (see where this is going ) ,,,,, i thought why not mock up the turbos

so off go the mufflers along with the headers and on go the manifolds:





which brought up the first issue of the day : the AC compressor has a small tab on the back that was hitting the manifold , as well as the manifold which had a small tab on one end to hold the heat shield on and that tab was hitting the AC compressor . so a quick round of the hack saw on both cleared up the dispute ( here is the tab on the compressor cutt off and the manifold tab still in place:



after that was sorted i put the mufflers back on; the plan is to re use the exhaust as it was initially built to be reused with the turbos. i wanted to line up the turbo outlets as much as i can with the existing exhaust to minimize the work needed later.
here is how much space there is and the locations of the exhaust pipes:



so after a few hours of mocking up and messing around with the position of the turbos , i had two cute little extensions welded on the manifolds that would place them as close to where i wanted them as possible:



and in case you ever wonderd how a pair of turbos would look like under an LS powered 996 porsche ,,, wonder no more













and thats when i called it quits for the day

so now whats left to do is a few braces to help support the pipe coming out from the manifold into the turbo flange, as well as a couple of supporting braces to help carry the weight of the turbo.

and that should be it for now when it comes to turbo hotside piping
all i have to do later is cut the u bend on the exhaust so i can connect it to the flex coupler you see in the pics. but i won't do that untill i put the new engine in .

so next up is to install the intercoolers on each side and figure out how to route and plumb the charge pipe from the turbo to the inlet of the intercooler. after that is done i'll take everything back off and reinstall the headers and exhaust for more "testing"
and install the manifolds and turbos on the new engine to plumb the cooling lines for the turbos. the plan is to use the rear steam vent holes on the back of the heads to feed the turbos water , and then plumb the return side to the suction side of the cooling system.

i should also start getting the new engine ready for the swap; from what i have scribbled down somewhere i have the following to do :

- get knock sensor to block adapters (i'm using ls1 style sensors and want to re use them on the LS2 block)
- oil sensor adapter on the the rear of the valley cover
- install the oil cooler sandwich adapter on the new pan
- turbo coolant lines
- figure out where i want to place the BOV

wish me luck



see what i can do with the

another thing i forgot to mention is that i was expecting that i had to remove the center engine mount brace thingy ( the brace you see mounted on the stock ls motor mount location) i can squeeze in a mushroom filter on there without removing the brace , or even add some ducting and mount the filters somewhere else.

and looking at the pictures you can't tell , but nothing hangs lower than the suspensioncenter brace