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Engine Cylinder / Liner
Fits:
Porsche 996 Turbo 2001-05
Porsche 996 GT2 2001-05
Porsche 997-1 Turbo 2007-09
Porsche 997-1 GT2 2008-09
Porsche 997-2 GT2 RS 2011
NOTE: These steel liners are a direct fit, requiring no modifications to the engine block.
Contents:
6x Forged Pistons (3xLH, 3xRH), 23mm pin, 9.4:1 compression ratio, 446g
6x Steel Liners Ø104mm bore, Ø107mm spigot (direct fit, 3894ccm)
6x Piston Ring Sets
6x Piston Pins (23mm)
12x Circlips for Piston Pins
Why choose this kit?
Nikasil-Coated Forged Alloy Barrels with Steel Liners:
Provides optimal slide characteristics and enhanced durability.
Optimized Forged Piston:
Manufactured using a specialised forging process for superior performance.
Desaxes Pin Offset for LH/RH Fitment:
The desaxing shifts the contact point before TDC, reducing piston wear and engine noise.
FEM-Optimised Centre of Gravity & Weight:
Finite Element Method calculations are used to optimise balance and weight distribution.
Special Bridged Design for Enhanced Stability & Longevity:
Offers superior structural integrity for lasting performance.
Precision Milled & Treated for Weight Reduction:
Advanced milling techniques reduce weight without compromising strength.
Deeper Valve Pockets (Inlet: Large, Outlet: Small):
Engineered for compatibility with high-lift camshafts to maximize performance.
Advanced Piston Rings:
Designed to minimise oil consumption and blow-by for efficient operation.
Compatible with VarioCam Plus:
Ensures seamless integration with VarioCam Plus for optimized engine control.
High-Performance Power Upgrade:
Delivers maximum power, torque, and agility for superior driving dynamics.
Thoroughly Tested on RS-Tuning Dyno:
Developed and rigorously tested to ensure optimal performance and reliability.
Related reference numbers
Related, superseded, cross reference or alternative numbers for comparison.
CAR103TT3900C
The product you are viewing cross references to these numbers
- Porsche 996 TURBO 2000-05
- Porsche 996 GT2 2001-05
- Porsche 997 MK1 TURBO 2007-09
- Porsche 997 MK1 GT2 2007-09
- Porsche 997 MKII GT2 RS 2011-13
Piston and Cylinder Set - 3.8ltr - 102mm - Slip Fit - 9.4:1
This Mahle 3.8-litre Piston and Cylinder Set is a
high-performance engine upgrade for Porsche 996 turbo, 997 turbo and GT2 RS
applications, combining 102mm forged alloy pistons with slip-fit ST52 steel
cylinders.
Fits:
- Porsche 996 TURBO 2000-05
- Porsche 996 GT2 2001-05
- Porsche 997 MK1 TURBO 2007-09
- Porsche 997 MK1 GT2 2007-09
- Porsche 997 MKII GT2 RS 2011-13
Designed for high-performance Mezger engine builds, the kit features a 9.4:1 compression ratio, deeper mirrored valve reliefs, offset piston pin bores and pre-installed piston rings.
What Does This Upgrade Do?
The 102mm bore allows the engine to be built to approximately 3.8 litres, providing increased displacement and the potential for greater horsepower and torque when combined with the correct engine components, turbocharger specification and ECU calibration.
Forged Mahle Pistons
Mahle's forged alloy pistons provide greater and more consistent strength than conventional cast pistons, making them well suited to high-output turbocharged engines.
A proprietary anti-friction coating helps reduce friction and wear while protecting the piston and pin bore surfaces.
The pistons also feature larger, deeper mirrored valve reliefs and use 23mm wrist pins.
Offset Piston Pin Bore
The piston pin bore is offset, or de-axiert, to help reduce piston noise and maintain quieter operation similar to the factory design.
ST52 Steel Cylinders
The cylinders are manufactured from ST52 steel, providing high strength and thermal resistance for demanding turbocharged engine applications.
The cylinders use a slip-fit design, simplifying installation without requiring machining of the engine housing for the cylinder fitment.
Pre-Installed Piston Rings
The sealing and oil-control rings are supplied pre-installed on the pistons, helping simplify assembly and ensuring the correct piston and ring combination is supplied as a complete matched kit.
Performance Potential
Increasing engine displacement can provide additional torque and horsepower, but final output depends heavily on the complete engine specification.
Turbochargers, camshafts, crankshaft configuration, intake and exhaust components, fuelling and ECU calibration will all influence the final result. Builds exceeding 700hp are possible with an appropriately specified engine and software, but this figure should not be considered a guaranteed output from the piston and cylinder set alone.
Key Features
- Mahle 3.8ltr piston and cylinder set
- Suitable for Porsche 996 Turbo / 997 Turbo / GT2 RS applications
- 102mm bore
- 9.4:1 compression ratio
- Forged alloy pistons
- ST52 steel cylinders
- Slip-fit cylinder design
- 23mm wrist pins
- Larger and deeper mirrored valve reliefs
- Offset piston pin bore for quieter operation
- Anti-friction piston coating
- Pre-installed piston rings
- Designed for high-performance turbo engine builds
- Complete piston and cylinder kit
- Made in Germany by Mahle GmbH
Mahle Porsche 996 / 997 turbo & GT2 RS Piston and Cylinder Sets
Mahle performance piston and cylinder sets provide a premium solution for Porsche Mezger engine rebuilds, displacement upgrades and high-performance turbo applications.
The combination of 102mm forged pistons, 9.4:1 compression and ST52 steel slip-fit cylinders makes this 3.8L kit particularly suited to Porsche 996 Turbo, 997 Turbo and GT2 RS engine builds where increased displacement, strength and performance potential are required.
Professional engine assembly, measurement and calibration are recommended to ensure correct clearances and compatibility with the complete engine specification.
Related reference numbers
Related, superseded, cross reference or alternative numbers for comparison.
100103038TU997
The product you are viewing cross references to these numbers
- Porsche 996 TURBO 2000-05
- Porsche 996 GT2 2001-05
- Porsche 997 MK1 TURBO 2007-09
- Porsche 997 MK1 GT2 2007-09
- Porsche 997 MKII GT2 RS 2011-13
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12 Month Warranty
Worldwide Delivery
Precision Engine Cylinders & Liners for Strong Compression and Long-Lasting Engine Performance
Engine cylinders and liners form the combustion chamber walls where the piston travels, making them critical components of any engine rebuild. High-quality liners ensure a smooth, durable surface that supports optimal compression, reduces friction and withstands intense heat and pressure. Over time, engine cylinders naturally wear, especially in high-performance or air-cooled engines, making replacement essential to restoring proper sealing and achieving long-term reliability.
Whether rebuilding a classic Porsche engine, repairing wear-related damage or upgrading to stronger, plated or coated liners, these components are crucial for achieving a stable, efficient and powerful engine.
What Engine Cylinders & Liners Do
Engine cylinders and liners perform several vital functions,
including:
- Housing
piston movement within a perfectly round, hardened bore
- Maintaining
compression for efficient combustion and power delivery
- Providing
a low-friction surface for smooth piston travel
- Managing
heat transfer between the combustion chamber and engine block
- Resisting
wear, scoring and distortion during high-load use
- Supporting piston rings to ensure effective sealing and reduced blow-by
Precision machining and high-quality materials are essential to ensure consistent engine performance.
Why Engine Cylinders & Liners Commonly Fail
Engine cylinders and liners work under extreme heat,
pressure and friction. Over time, wear and damage can occur due to conditions
such as:
- Cylinder
scoring from debris, poor lubrication or contaminated oil
- Heat
distortion, especially in air-cooled or high-performance engines
- Loss
of roundness due to age, high mileage or detonation
- Piston
ring wear, causing uneven polishing and loss of sealing
- Corrosion
from moisture or poor-quality coolant
- Incorrect
fuelling or tuning, increasing combustion temperatures
- Overheating, weakening internal surfaces and coatings
Failing cylinders lead to low compression, high oil consumption, smoke, reduced performance and misfires.
Why You Should Replace Worn Cylinders & Liners
Replacing damaged or worn cylinders with precision-engineered alternatives designed to match original specifications and performance characteristics ensures your rebuild is durable, efficient and reliable.
Key benefits include:
- Restored compression and improved combustion efficiency
- Reduced oil consumption and blow-by
- Stronger resistance to heat, scoring and detonation
- Longer engine lifespan and smoother performance
- Better support for high-output or performance builds
- Improved sealing for higher efficiency and power delivery
- Protection against catastrophic engine wear or failure
New liners or cylinder replacements are essential for any proper engine restoration or performance rebuild.
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