Sweet Victory's 2001 C2 Aero

Each Outpost member may create a post in this thread to track maintenance of their vehicle, including PM, repairs, etc.
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sweet victory
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Sweet Victory's 2001 C2 Aero

Post by sweet victory » Fri May 31, 2019 9:27 pm

I've been slacking off with documenting maintenance on my 996, so I figured starting a thread here will kind of help aid in resolving that and act as sort of a photo journal. I have receipts of the major maintenance work since 2008 when a Porsche re-manufactured motor was installed. Here is a brief summary up until now:

09.29.2008 | 50,234
  • Alignment
11.25.2009 | 58,250
  • PCA Tech Inspection
01.27.2010 | 59,571
  • 60K Major Service
04.30.2010 | 60,048
  • Replaced brake pads
  • K&N Intake Install
05.06.2010 | 61,121
  • Tech Inspection
07.05.2010 | 66,742
  • Rear Main Seal
  • Clutch
  • Pressure Plate
  • Flywheel
  • Pilot Bearing
  • Release Bearing
  • Clutch Release Arm
  • Gear Oil
12.03.2010 | 69,684
  • Air Oil Separator
01.29.2011 | 70,800
  • Air Mass Meter
08.30.2011 | 77,544
  • Bilstein PSS10 Coilovers
11.15.2011 | 79,322
  • Steering Lock Housing Switch
06.29.2012 | 87,692
  • High Pressure Power Steering Hose
  • Power Steering Fluid
  • Serpentine Belt
07.03.2012 | 87,797
  • Water Pump
  • Water Pump Gasket
  • Coolant Expansion Tank Cap
01.25.2013 | 91,289
  • Oil
  • Oil Filter
  • Transmission Fluid
04.02.2013 | 91,642
  • IPD Plenum
  • Fabspeed Maxflo
  • ECU Tune
08.15.2013 | 93,114
  • Brake Rotors
  • Brake Pads
  • Brake Pad Sensors
  • Brake Fluid
12.04.2013 | 98,603
  • Alignment
02.27.2014 | 100,948
  • Air Oil Separator
  • Spark Plugs
06.29.2015 | 111468
  • Camshaft End Plug
  • Camshaft Cover Piece


Ownership Change @ ~113k Miles



12.01.2015 | 115,521
  • Oil
  • Oil Filter
  • LN Engineering Magnetic Drain Plug
07.22.2016| 120,724
  • Oil Filler Neck
  • Oil Filler Neck O Ring
  • Oil Filler Cap
  • Serpentine Belt
    Note: Cleaned throttle body, broke AOS plastic cooling line fill neck replacement. Adapter replaced with double barb end coupler.
09.09.2016 | 122,489
  • Rauch & Spiegel SS AOS Cooling Adapter
11.25.2016 | 125,452
  • Oil
  • Oil Filter
  • Rebuilt Air Injection Pump
03.05.2017 | 130,384
  • Oil
  • Oil Filter
  • Goodridge Stainless Brake Lines
  • Brake Fluid Flush
  • Transmission Fluid (Motul)
12.05.2017 | 134,578
  • Oil
  • Oil Filter
  • Fuel Filter
01.09.2018 | 134,924
  • MA Shaw GT2 Wing Installed
  • Side Skirts Repainted
02.24.2018 | 136,558
  • Numeric Racing Shifter
  • Numeric Racing Billet Cables
  • BBE Headers Installed
  • Header Gaskets
  • Exhaust Manifold Screws
  • Header Flange Bolts & Nuts
04.09.2018 |137,745
  • Front Bumper Repainted
  • Radiators Cleaned
06.01.2018 | 139,515
  • Oil
  • Oil Filter
09.20.2018 | 140,087
  • Driver Set Door Lock Mechanism
    Note: Replacement unit defective and replaced.

10.26.2018 |140,364
  • Air Mass Meter
11.11.2018 |140,895
  • Coolant Expansion Tank
  • Coolant Expansion Tank Cap
  • Coolant Level Sensor
  • Water Pump
  • Water Pump Gasket
  • Thermostat
  • Thermostat Housing Gasket
  • 3 Way Coolant Hose
  • Coolant
03.01.209 |142,984
  • Rebuilt Starter Motor
  • Rebuild Air Injection Pump
  • Installed OEM 997 3.8 Intake
Last edited by sweet victory on Fri Jan 17, 2020 4:05 pm, edited 3 times in total.

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sweet victory
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Re: Sweet Victory's 2001 996 C2 Aero

Post by sweet victory » Fri May 31, 2019 9:27 pm

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sweet victory
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Re: Sweet Victory's 2001 996 C2 Aero

Post by sweet victory » Fri May 31, 2019 9:33 pm

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sweet victory
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Re: Sweet Victory's 2001 996 C2 Aero

Post by sweet victory » Fri May 31, 2019 10:45 pm

05.31.2019 | 143119
  • Oil
  • Oil Filter Housing
  • Oil Filter
    Note: Switched from 0W-40 to 5W-40.
I finally got to use a real oil catch can with my Danmar lift. Got to love zero mess!

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Oil Filter dissected and thoroughly inspected. All is well here. It looks shiny in the photo, but it's just the lights above reflecting off the oil.

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Picked this up from Suncoast a while back, and finally got around to using it. It was something like $20ish for the kit, so I figured why not since I have no record of it ever being replaced.

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Also got to try out a new tool today. It's a spout that screws to the cap and provides a spill free oil change. I got two of them; one for oil and one for coolant.

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It screws into it self, so it doesn't leak everywhere when you store it.

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sweet victory
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Re: Sweet Victory's 2001 C2 Aero

Post by sweet victory » Sat Jun 08, 2019 4:42 pm

06.07.2019 | 143119
  • Coil Pack Heat shield Upgrade
Wanted to tinker in the garage on Friday night. Making a list of maintenance items to do at ~145k miles and I went to inspect the condition of the coil packs, since my spark plug tubes are beginning to weep. (No leak yet, but it's getting that dusty oily build up starting around that area) Figured since I removed the heat shields, I would go ahead and practice applying Design Engineering heat reflective sheets. Don't ask me why; I just wanted an excuse to play with this stuff. There is a drastic difference between the real stuff and fake copies; the real stuff has a fiber weave in it, so if the tape doesn't look textured, it's a good indication it's fake.


I started by prepping the heat shields; degreased and used a roloc scotchbrite pad to scuff up the surface.

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After my first attempt, I decided to use masking tape where I knew I would be removing the shield. The adhesive sticks REALLY well, and if you try trim and cut it, it delaminates and is a pain to remove the fibers still sticking to your surface. Having the layer of masking tape definitely led to a better end result.

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Since the surface has a lot of curves, this is actually a pretty difficult piece to "wrap" for a first timer. Having smaller strips instead of one large piece would probably help to minimize that, but I had only purchased a large sheet and wanted to try doing it in with one piece. The gold layer tears very easily, so you have to constantly have a sharp edge on your razor, and the fiber glass weave can be difficult to cut. Scissors leave a nice edge, but probably only realastic to make precut templates for flatter pieces.

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The end result still came out decent. No data or anything to justify doing it; just wanted to play with a new material.

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sweet victory
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Re: Sweet Victory's 2001 C2 Aero

Post by sweet victory » Wed Dec 04, 2019 10:23 pm

12.04.2019 | 143170
  • Battery Replaced

The car hasn't been getting driven enough. Between taking on a new mountain of responsibilities at work, getting a company vehicle for daily commuting, and working on home renovations, less than a hundred miles got put on the 996 in the past few months. I decided that it needed some TLC, so I splurged on some new Adam's detailing equipment since they opened a physical store in OC, roughly 15 minutes from my office. One of the items I picked up was their ceramic coating. Over the course of a few weekends, I would chip away at the paint correction process panel by panel. When I was roughly 75% complete with this, the battery on the car lost a cell. I accidentally left the decklid open for a week and it drained the battery to about 4V. I had it on a charger for 2.5 days and it wouldn't hold a charge about 8.5V. Given it was over 5 years old, I couldn't complain.


I figured since the battery would come out, and I was detailing the car, I cleaned up the compartment space and checked the water drains. The drains were completely clogged! This is a SoCal car that is garage kept, so was pretty amazed to see how much build up there was in there!

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Good as new-ish.

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The battery tray was a little crusty, so cleaned that off too. The threads in the battery tray had some battery acid/corrosion/funk in them, so cleaned those out and preserved it with Fluid Film.

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New Interstate H6 battery from Costco.

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sweet victory
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Re: Sweet Victory's 2001 C2 Aero

Post by sweet victory » Wed Dec 11, 2019 11:42 pm

12.09.2019 | 143170
  • Adams Ceramic Coating
Chipped away little by little over the weeks performing a paint correction and then applied Adams Ceramic Coating. Looks stunning. Have to fly out for the holidays, so pics will have to wait for now. :(

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Post by sweet victory » Sun Dec 29, 2019 9:31 pm

12.29.2019 | 143269
  • Inspected Suspension Components & Bushings

After returning from visiting family for the holidays, I took the 996 out for a drive. The last time I drove it, I felt some vibration through the steering wheel. I figured I would see if the vibration persisted to make sure it wasn't just flat spots on the tires or anything like that. A few weeks later, I still felt the vibration so I did some digging.

I removed all the wheels and cleaned the wheel/hub interface to make sure there wasn't any crud preventing the wheel from sitting correctly. Thoroughly inspected mounting points, and found I will need sway bar drop links and thrust arm. The sway bar link dust boots have completely failed (passenger & driver side), and the passenger side thrust arm dust boot is starting to fail. Top hat mounts look tired, and are showing cracks. I'm not sure how thick the rubber in the top hat is, but I'm also looking for reasons to upgrade to monoball top hats. :D

Driver Side:

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Passenger Side:


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When pushing wheels side to side and felt no play. I read that the best way to check for inner tie rod end play is to disconnect the tie rod end and pull/push from there. I did this on both sides, and felt no play.

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When pushing wheels up and down, I felt some place on the front driver side wheel. I will need to replace this wheel bearing. I already own an OTC Hub Grappler kit, so I can change the bearing without removing the upright. I'm hoping this is the source of the vibration I'm feeling when I'm at ~70mph. I did not see any signs of missing wheel weights.

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Re: Sweet Victory's 2001 C2 Aero

Post by sweet victory » Fri Jan 17, 2020 4:06 pm

01.15.2019 | 144389
  • Observed Idle Fluctuation Between 740 - 800 RPM
Put about a 1000 miles on the 996 since the beginning of the year - I sure missed driving this car! As the car climbs in miles, I'm expecting and looking for signs of wear and tear. (I look for any excuse to buy tools and stuff ). After today's drive, I noticed the idle slightly fluctuating. I plugged in my durametric tool and found the idle to be fluctuating between 740 and 800rpm with the AC off. It's something I noticed after I reversed into my garage and could hear the change in exhaust note. It's been a while since I changed spark plugs, cleaned the throttle body, etc. so I'm probably due for some maintenance at 145k. I have a bunch of parts accumulating that I need to get to anyways. With all this talk of AOS going on in the forums, it's probably time I invest in a manometer to check the health of my AOS. I've never had a hard to remove oil cap, or sooty tail pipe, so I haven't had reason to believe my AOS has failed ..yet. I do recall seeing a light film of oil in the intake runners when I serviced my starter, so chances are it's beginning to fail. I'll know for sure soon.

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5chn3ll
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Re: Sweet Victory's 2001 C2 Aero

Post by 5chn3ll » Fri Jan 17, 2020 4:38 pm

I'd offer to loan you my manometer, but they're cheap enough on Amazon that the freight out and back would pay for one outright. Looks like the one I bought is off-patent now - there are about 200 clones that look suspiciously similar to mine...

Understeer: You will hit the wall with the front end.
Oversteer: You will hit the wall with the rear end.
Horsepower: How hard you will hit the wall.
Torque: How far you will move the wall.

Gone hunting with Alec Baldwin and Dick Cheney. Back soon.

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