ENGINE REBUILDS – AxellRacing Performance Engineering

Porsche Engine Rebuilds

2005 Porsche Cayenne Turbo S (955) 5.7 litre (originally 4.5 l)

(Mouse-over photos for captions.)

Head new assembly, cleaned pistons, new rings

Starter, water pump, top end water lines

Diagnosis: engine had 150,000 miles, was performing poorly, and was consuming excessive amounts of oil, and oil smoke coming out of the exhaust. Compression tested all cylinders: cylinder 8 had no compression. Cylinder 7 was 50% compromised. Remaining cylinders were 20 – 40% compromised. Scoped all cylinders and discovered bore scoring in cylinders 7 & 8.

Remedy: to save this vehicle from the scrap yard, an engine rebuild was preferred.

Engine removal
Top end disassembly
Bank 1 & 2 head, dip tank and cleaned. Deck and p0lished head, port/polished intake and exhaust runners, cleaned oil runners, honed/polished valve seats (16), line honed valve guides, compression tested valve springs and installed with new valve seals (16)
Salvaged short block – dip tank and cleaned
Measured existing bore, deglazed and honed cylinder sleeves, re-measured set ring gaps
Deck block, bank 1 & 2
Cleaned/removed carbon, installed rings and pistons for cylinders 1 – 8 including connecting rods, and honed bearings
Installed new crank bearings and line honed
Cleaned and installed oil squirters
Installed main crank, torqued connecting rods
Measured for proper end play
Installed new main seal
Measured with denatured alcohol: cylinder volume @620 ml + head volume @50 ml = 670 per cylinder x 8 = 5,360 ml (5.36 l) + head gaskets @340 ml = 5,700 ml (5.7 l) actual volume.
Installed bank 1 & 2 heads with new head gaskets and bolts
Installed bank 1 & 2 lifters
Installed all 4 cams
New timing chain and guides
Set timing
Timing chain cover cleaned and detailed
Bottom end assembly
Oil pump and drive chain; connected return link from crank shaft to oil pan
Cleaned and reinstalled oil pan
New water pump
Rear water housing
New starter
Reinstalled all sensors
Water tube from rear housing to pump
Replaced water tube connector hose
Installed upper water tube thermostat
Installed bank 1 & 2 cam covers
Installed oil pan
Installed wiring harness
Installed alternator
Installed A/C pump
Installed power steering
Installed new lower cam vacuum lines
Installed new plugs and coils
Installed air intake
Fuel rail and injectors – cleaned and replaced micro filers, seals, and flow tested
Ceramic-coated exhaust headers
Installed oil cooler
Rebuilt both turbos – new impellers and seals, and installed
Installed rear coolant lines
Installed oil lines
Installed new upper cam vacuum lines
Reinstalled engine and transmission, filled all fluids