Swapping engines

[piper6909]

Originally Posted by LoneWolfGal

Note the rubber hose connected to the fuel rail. Then note the crimp next to its metal sleeve. The hose got munched when they packed the engine for shipping. Haven't priced a replacement yet.

To me that looks more like someone twisted the hose during installation. I can't see how packing would cause that, unless they put a banding strap over it.

What's that hose for? Can't you pull one off your other engine?

[78F350]

Originally Posted by piper6909

To me that looks more like someone twisted the hose during installation. I can't see how packing would cause that, unless they put a banding strap over it.

What's that hose for? Can't you pull one off your other engine?

That's fuel return at the pressure regulator. It should be easy to pull from the old engine.

[elgyqc]

Originally Posted by piper6909

To me that looks more like someone twisted the hose during installation. I can't see how packing would cause that, unless they put a banding strap over it.

What's that hose for? Can't you pull one off your other engine?

That is a fuel line, I think the return.
As suggested by piper... use the old one or:
- has the kink really damaged the line?
- if so a shop that deals in hydraulic equipment may be able to fix it for less than the Porsche part.

[LoneWolfGal]

Originally Posted by elgyqc

That is a fuel line, I think the return.
As suggested by piper... use the old one or:
- has the kink really damaged the line?
- if so a shop that deals in hydraulic equipment may be able to fix it for less than the Porsche part.

Good suggestion, Grant. I'd like to straighten it, but I'd worry that the walls of the line were compromised. A hydraulic equipment shop could probably tell me definitively. I will look over the line on the old engine, as Al and 78F350 recommended. And I'll find out how much a new one costs — but I remember pricing the small plastic tube to the regeneration valve I replaced under the bank 2 intake manifold, and it made my hair stand on end. I ended up splicing in a short length of 5/16" rubber fuel line with hose clamps.

[LoneWolfGal]

Talked to Pelican. They said Porsche calls it simply a "fuel hose," and Pelican would need to order it from Porsche. It's #8 in the exploded view below:



The discounted price for a Genuine Porsche replacement through Pelican: $280.

Seems a little high...

[78F350]

[LoneWolfGal]

Yes, I figured that out, but thank you. Could you point out D3 on the panel itself? That's what I'm scratching my head about.

[78F350]

Originally Posted by LoneWolfGal

... Could you point out D3 on the panel itself? ...

[LoneWolfGal]

Much obliged, 78F350! That's exactly what I needed. I'll check that fuse, but it could easily be the relay instead. Relays get corroded. Tapping it on a hard surface like a pack of cigarettes often fixes the problem.

[78F350]

Any chance that the motor for the top was disconnected while you were around the engine compartment?
Here's the Pelican Parts DIY for top repair which may or may not be helpful: https://www.pelicanparts.com/techarticles/Boxster_Tech/71-BODY-Convertible_Top_Repair/71-BODY-Convertible_Top_Repair.htm

Somewhere I've got a troubleshooting chart for the relay. It may be hidden in the Bentley Manual somewhere too. Here's a post from 997_986 that looks like it has the same procedure: https://986forum.com/forums/662149-post7.html



Here's a picture of feral cat 'Handsome Dan'. He's very playful for a feral:

[LoneWolfGal]

Originally Posted by 78F350

Any chance that the motor for the top was disconnected while you were around the engine compartment?

Excellent question. But in the interest of expediency I'm taking another tack: I'll lower the top manually. Just as soon as I find out how to do it.

[piper6909]

If you have a multimeter (or even a test light), I found this that 997_986 also posted:

I recommend checking these points before you test it with a new relay...

TROUBLESHOOTING ON THE RELAY CONTROLLER
Note: Control relay disconnected. The terminal designation on the relay (Fig. 596_97) is from the underside of the control relay.
1. connect the measuring device (voltmeter) to terminal 22 (earth) and terminal 23 (plus 30) on the relay plate. Display = battery voltage
2. connect the measuring device to terminal 22 (earth) and terminal 26. Switch on the ignition. Display = battery voltage
3. connect the measuring device to terminal 23 (plus) and terminal 15 (handbrake applied). Display = battery voltage
4. connect the measuring device to terminal 23 and terminal 16 (close soft top button). Press close button. Display = battery voltage
5. connect the measuring device to terminals 23 and 17 (open soft top button). Press the open button. Display = battery voltage
6. convertible top locked . Connect measuring device to terminal 23 and terminal 14 (microswitch wind frame). Display = battery voltage
7. convertible top locked . Connect the measuring device to terminals 23 and 29 (microswitch B-pillar). Display = battery voltage
8. top unlocked. Connect the measuring device to terminals 23 and 13 (microswitch closed, soft top compartment lid VDKD open). Display = battery voltage
9. convertible top unlocked . Connect the measuring device to terminal 23 and terminal 19 (microswitch wind frame). Display = battery voltage
Connect control relay to relay carrier. Open the soft top compartment lid and disconnect the electrical plug connection on the drive motor-top drive.
10. connect the positive of measuring device to terminal 1 (black cable) and the negative of measuring device to terminal 4 (green cable). Kl. 2 and Kl.
11. connect the positive of measuring device to terminal 4 (green cable) and the negative of measuring device to terminal 1 (black cable). Bridge terminals 2 and 3 with an auxiliary cable. Switch on the ignition and press the "Close" button. Display = battery voltage

Btw, afaik from 2000 onwards there are only two microswitches, one in the lock and the other in the planetary gearbox. No microswitch on the bracket of the motor.


The above, along with the diagram 78f350 gave you, will help you determine the health of the circuits and hopefully rule out either a mouse chewed out some wires or a bad relay.

For example, if you get no voltage when you test the handbrake circuit (test #3), but you have a handbrake light on the dash then you know the switch is fine, but there's a break in the wire before the relay.

I have to admit, test #10 has me puzzled as I don't know what they mean by "KI. 2 and KI."

But the other tests seem straightforward.

[LoneWolfGal]

I'm shelving the issue with the insubordinate top mechanism for a while, because my cam timing kit arrived today. It's much larger and heavier than the IMS kits. I'm very pleased with the quality of the Chinese parts. Not sure what those long tools are used for, but I don't think I'll be using them during this procedure. Perhaps someone can shed some light on their function. Tomorrow I'm going to press this kit into service. Putting the top in service mode can wait until the new pads are installed and the cams are timed. Lexi, my Jack Russell Terrier, is eyeballing the kit with skepticism in the photo, but I think it's well worth $97.

[piper6909]

Originally Posted by LoneWolfGal

Lexi, my Jack Russell Terrier, is eyeballing the kit with skepticism

Awww Lexi!

Never underestimate a dog's intuition!

[Gilles]

The long white nylon tool is used to insert the pistons circlip during assembly

[LoneWolfGal]

Originally Posted by piper6909

To me that looks more like someone twisted the hose during installation. I can't see how packing would cause that, unless they put a banding strap over it.

That's exactly what they did — it was under one of two wide nylon ratchet straps, strapped tightly around the engine. The hose is the only casualty. All the other hoses, tubes, wiring looms, and connectors look almost new. I really have no complaint. Whoever pulled the engine took exceptional care to disconnect all hoses, etc., making sure they remained intact, rather than simply cutting them for expediency. Had they done that, I probably would have passed on this engine.