Porsche 996 turbo factory power steering fluid is Pentosin CHF202, not compatible with powersteering fluid that the LSx would use. Did you flush out the factory the fluid really well? Not even sure if the rack seals would be compatible.

 

as far as i remeber it was dry when i got it
the plan now is swapping to an electric pump to get rid of this mess

 

Yea...and grab your *** when you see the price of this stuff. I had to use it in my wife's 'Benz when I flushed her p/s system. I about died.

 

looool, i know i choked when i heard how much a quart cost !

 

time for a minor update

like i said i got the electric water pump in , so i dropped it in the car after welding a bracket for it on the passenger side and finished all the hose connectiones , also vaccume filled the cooling system and wired the pump to work when the fuel pump works . only problem is i forgot my laptop so i couldn't log the temps so i didn't start it
anyhow here is how it looks :



in other news i found out that the broken master cylinder feed line that i fixed before broke again (guess brake fluid and crazy glue don't mix ) , so i JB welded it this time till i get the new one in . i also ordered an electric power steering pump which should be here real soon.

also got a bunch of prebent aluminum tubes so started working on the intake Y again , its a slow process but should work out real good now and later: the intake tubes will snake all the way to the ports in the side of the engine compartment ( where the intercooler outles poke out originally) where the will attatch to a set of filters for now , and when i fo FI all have to do is just put the intercoolers in ther and connect them to the same Y pipe .

i also finished wiring the coolant temp sensor , so in theory it should work now
(still didn't trace and check the oil pressure wires )

so next up is testing that the car doesn't overheat at idle , tune the idle (it has a base tune now, won't hold idle when i first start it and its running super rich - plugs were fouling ) , fill and bleed the clutch hydraulics, install the hood latch actuator when it comes in , mess with the intake tube some more, and i have to remind myself to put some gas in the thing

off course all this has to wait till i come back home in a week or so, and pending other to-do's on other projects . so if the cooling system proves itself i might start taking it out for longer "testing" sessions

 

Great work man. I've been poking around the site for quite a while. My buddy has a 996 (non-turbo) and had been talking about doing the swap since rear main is looking leaky. He pointed me to your build so I ran through it all. Have to say, very impressive.

I don't know if you're familiar with other varieties of LS engines, but we were considering an LS7 swap (little more displacement, and dry sump). However I wasn't sure if the engine dimensions would be prohibitive to doing the swap, or if it's the same basic dimensions as the LS1's. You can find used LS7's around the states for a decent price still, so figured might be worth a shot.

Also definitely interested in a full parts list once you get it compiled

again awesome job, looking forward to seeing this thing done!

 

thanks dualdj1 !
the LS7 is basically the same engine deimentionally , only difference would be the bigger oil pump bulge behind the balancer and the oil pan setup. it should fit just fine only issue would be the drysump tank . or you could just convert it to a wetsump system and skip the hassle

any how , one more update before i skip town for the weekend ( our weekend)

i fixed the master cylinger reservoire tube and installed it , all i have to do now is hope it doesn't leak and bleed it .

then i proceeded to the idle test , i fired it up and let it idle for 35 minutes and the highest it ever reached was 190 degrees
which means the cooling system is officially done !

in other good news , the temp guage also works ,,,,, and apparently when id does so does the oil pressure guage too

( i was so happy that all i had to do now is the RPM sensor and fuel level relearn i decided to snap a pic of the dash )



so after finishing with the cooling deal, i went back and started messing withthe intake tube.
i already built two Y's but i couldn't get either of them to fit like i wanted .
so i decided to go with a different approach ; basically a small section of 4" aluminum tube with two 3" 45 degree tubes going into the 4" tube . this should get me the needed clearance i need to clear the hood latch .
anyhow , here is what finished so far :



and as usual , the to do list for next time :
-bleed the clutch
-more intake fabrication
-build a crank sensor bracket
-more stuff but i'm too tired to think about

 

Lookin' good. Which electric water pump did you end up using. Sorry, if I missed it. Browsed through, but, didn't see it noted.

 

you're right , i don't think i mentioned it before

its a mezerie single inlet/outlet inline pump.

 

Thanks. I've been thinking of adding an LSX 911 Targa to the stable. Although, probably should continue & finish the 944 build first. You know how it is; always considering a number of different builds. It's just part of the insanity.

 

So did you get rid of the belt driven water pump? Or just get the electric one as a supplemental pump? If you got rid of the mechanical pump what other adapters and such did you need?

 

sorry for the late reply but been busy with a bunch of stuff

the pump is a complimentary one , the stock one still does its duty .


well i got some progress and "regress" to report

in progress news , i finally got around to tuning it ( well,, idle and tip in tunning ) and now she purrrrrrs the thing was ideling at 10:1 AFR before , which explains the fouled plugs and the sluggishnes.

i also finished mounting and wiring the porsche cranks sensor , so now i have a working RPM guage so now all the dash guages work propperly , and all that is left is to tackle the small warning lights .


and in the not so good news side, the damn master cylinder fix didn't work and it leaked again , so all that hard wrok bleeding it went to waste and i now have to wait till the new part to show up

and in other crap ,,, i decided to change the non functioning engine compartment latch but that still didn't fix it , which meant i had a problem with the wiring .
so i started tracking it back into the driver side rear corner inside the car . now i never really looked into that corner because most of the wiring i messed with was on the passenger side corner, and i issumed that since the the passenger side wires were slightly burnt and stiff , the other side couldn't be worse ,,,,,,, well man was i wrong :





the wiring was burn't to a crisp ! and not just that , the damage extended to other sections of the harness ( i never took a really good look at the harness like i did lately ) which could explaing the sensors not reading and the brake light issues and what not, and potentially being a short and fire hazard down the road.

so the next step was to fix it i decided to cut and "patch" the offending part of the harness , which meant i had to seperate the wires one by one so i can track their colors ,,,,, fun!

well after more than 2 hours into it this is where i ended up :





and it was obvious this was going to be a huge - and frustrating task (given my love of wiring ) so i looked into getting a replacement harness and thans to the awsomeness of Ebay , i'm now waiting for the new - un burned, un stiff - harness to show up

so this pretty much sums up what i have been doing lately, so later on i'll be ripping the old harness out in anticipation of the new one getting here, fixing the master cylinder again , replacing the driver headlight bracket, dropping in the dash and door airbag covers, messing with a few odds and ends here and there ( can't remeber what right now )


in hind sight , why didn't i just rip all the interior out of the car and inspected and redid what ever was damaged then assembeled every thing back in ? (guess it didn't look as bad when i first looked at it )

 

Wow. Your are lucky you decided on checking that harness out sooner than later. My luck would of been a fire as soon as I thried to start the car with the LS1.

Keep up the good work.
Jim

 

i guess the thing that saved me from bbq'ing this thing again was the fact that there was nothing hooked up to that side ( lic. plate lights, brake light , parking sensors , latch release, etc) , or i was just lucky

any how , while waiting i'll try to lean the place some more and slap on some insulation mats to make it look nicer

 

maybe once youve got the whole thing done you could get a stock replacement harness, that way you know what all modifications that need to be done to make it suit your purpose but it will have not been cooked in a fire

 

thats what i did , i already ordered a stock replacement and will be splicing in the other stuff when i get it .

on a side note , i managed to rip the whole rear harness out of the car , and man was it a pain in the donkey , i had to remove half of the interior to get the damn thing out !

but on the positive side, i can now insulate the whole *** end of the car

 

Wow that's crazy lol. Hate to say it, but you know what they say about assuming... At any rate, glad to see you caught it and can get it fixed properly.

That's the only major downside about a non-running donor car, it's easier to miss things like that.

What's next on the list following the harness replacement, insulating, and master cylinder?

 

ac, some interior stuff , the harness, slap the bumper on and off to bodywork

 

made it to the front page of possibly the biggest car forum in the UK

http://www.pistonheads.com/news/defa...?storyId=23834

 

looool , got to love other people's opinions

not much to report i guess, other than the new harness arriving today .
i sat down and started cutting out all the unnecissary wires from it before i put it in , and i guess i found a few surprises : the good one is that i have all the missing connectors and burnt ones before (third brake light, brake sensor plug etc ) , the bad surprise is that the harness is not for that specific car , i couldn't find the alt. charge indicator light, and the rear wiper plug is not available and so on . and the worrying thing is that on the side connectors ( just next to the driver and passenger hips) there are a few missing wires and a few extra ones, and there is a small computer thingie on the passenger side that had part of the old harness plug into , but the new harness does not have any provisions for that ( i'm assuming its the transmission contoller when the car was an automatic).

anyhow , after a few hours of cutting and splicing and routing the harness ( man does it feel good to work on a dry, non- gooey harness ) i think i have the thing almost done , i just need to jack the car up and remove the rear tires so i can connect the brake sensor, speed sensor, headlight level sensor, and what i think is the reverse light sensor thingie.

i did cycle the ignition and the water pump worked, and so did the fuel pump which means the LS1 PCM is working. the bummer is that the hood release thingie still doesn't work! i still have to dig into the diagrams and see what i can do , worst case scenario i could just rewire the latch.
another thing that caught my attention is that i got an airbag warning on the instrument cluster
and did i mention that JB weld and brake fluid don't go well together? the master cylinder was leaking and after inspecting it i found that a small repair i did didn't go as planned i should have the fix by tomorow.

so i'm hoping tomorow to connect the brake lights and see if they work now, replace the headlight bracket , install the airbag covers , bleed the clutch and start the car and let it idle for a while to see if everything else works
if it all goes ok ( i hope ) then the interior goes back in and off to the AC shop !