Yes, removing the Mezger is that daunting.
The one chink in the Mezger’s armor is its flimsy coolant pipes. For such a bulletproof motor, it seems strange that Porsche just glued the coolant pipes on. Though press-fitted, these coolant lines are known to pop off under high RPM load. Hoovie’s lousy luck meant his first trip to Heartland Motorsports Park was interrupted by his own lines popping off. Fortunately, this did not prompt a spin down the front straight, nor did it cook the motor. It was embarrassing though, and as it turned out, quite pricey to mend.
The Mezger motors that see the track will sustain higher temperatures and loads which are prone to make these lines disengage from the coolant console, and ensuring they stay in place during hard cornering and high revs requires a costly fix. While the cheaper band-aid fix would only set him back a few hundred dollars, the sensible approach costs ten times that. After dropping the engine, the hoses need to be pinned or welded in place, and the especially prudent drivers will replace the problematic OEM plastic elbows with stainless steel units.
The process of removing the engine is more labor intensive than dropping an M96. Turbos, intercoolers, head shields, and all the other forced induction ancillaries take a bit more time and effort. The starter and turbo inlets need to come out too, since they won’t clear the CV axles. With a few minor wiring hurdles cleared, the Mezger can be freed from its cramped confines. However, the process takes Hoovie and Wizard nearly two whole days to complete—which is why he was quoted nearly three large.
If there’s one piece of uplifting news here, it’s that BBi Autosport decided to help by offering to fix the busted water pipe situation. BBi, as well as a host of other Porsche-centric shops, can weld the coolant pipes in place for what should be a permanent fix. If you have any Mezger-powered Porsche, be it a Turbo or a GT3, you can preemptively have this work done, so it doesn’t come apart and leave you stranded without coolant. If you can remove your motor to get the “coolant console” out, as Mr. Hoover has, it’ll help save you a ton of labor.
Now you know. Let his misfortune save you a ton of time and money!
