04-25-2018, 01:43 PM
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#1041
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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House started the swap this morning at 9am. The old engine was out after lunch.
The pro's make it look easy (as compared to my hack DIY skills!).
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1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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04-25-2018, 06:59 PM
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#1042
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Registered User
Join Date: Oct 2012
Location: claremont, ca
Posts: 47
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So a 3.8L is going in Tom, I am sending the scrutineers
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04-25-2018, 08:29 PM
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#1043
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Quote:
Originally Posted by bkovac
So a 3.8L is going in Tom, I am sending the scrutineers
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3.8's are soooo 2016. I assure you it'll be a 4.0 liter.
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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04-25-2018, 10:09 PM
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#1044
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Registered User
Join Date: Feb 2017
Location: CO
Posts: 989
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Quote:
Originally Posted by thstone
House started the swap this morning at 9am. The old engine was out after lunch.
The pro's make it look easy (as compared to my hack DIY skills!).
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Tom... is it just the picture being somewhat distorted, or is that UDP all bent to hell?
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04-26-2018, 07:59 AM
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#1045
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Quote:
Originally Posted by Geof3
Tom... is it just the picture being somewhat distorted, or is that UDP all bent to hell?
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I didn't take the photo so I don't know for sure but I'm going to guess that its a distorted photo. I plan to drop by the shop today and I'll confirm.
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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04-27-2018, 10:22 AM
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#1046
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Everything has been swapped over and the replacement engine has been installed in the car! They should have it running by the end of the day. 
They'll drive it on Monday to make sure that everything is ok and it should be ready for pickup on Tuesday.
The small pile of parts to the right of the top is the tip wiring harness, a/c compressor and lines, exhaust manifolds, and alternator (the bearing sounded rough so they swapped in the old one). The idler and tensioner pulley's were also replaced with new components since they were rough sounding.
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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04-27-2018, 10:23 AM
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#1047
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Quote:
Originally Posted by Geof3
Tom... is it just the picture being somewhat distorted, or is that UDP all bent to hell?
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Photo distortion. The UDP is fine. 
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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04-27-2018, 10:36 AM
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#1048
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Ok, check this out....
Here is the oil filter from the failed engine just as it came out of the engine. It looks like the oil pump was sucking so hard that it collapsed the filter. Is that possible? Weird. 
There wasn't any metal in the oil or the oil filter but the shop said that they found coolant in the oil when they drained it. There is also a ton of oil in the intake runners. I plan to get the engine back to my workshop and will disassemble it to try to determine the exact failure.
And at the bottom is a pic of the failed engine looking pretty sad after being raided for parts to swap onto the replacement engine. 
 
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
Last edited by thstone; 04-27-2018 at 10:38 AM.
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04-27-2018, 11:57 AM
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#1049
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Registered User
Join Date: Dec 2016
Location: Clifton, NJ
Posts: 1,135
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blown AOS resulting in a broken ring?
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04-27-2018, 03:52 PM
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#1050
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Registered User
Join Date: Jul 2008
Location: austin
Posts: 824
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Quote:
Originally Posted by Quadcammer
blown AOS resulting in a broken ring?
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I'm thinking that's the case -- was there any smoke out the back?
Mike
__________________
Drivers: '15 Panamera Hybrid (wife's), ' 01 996 GT2, 00 Boxster S, '96 993 Çab/Tip (wife's)
Race Cars: '75 911 RSR Replica & '99 Spec Boxster
mike@lonestarrpm.com
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04-27-2018, 04:40 PM
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#1051
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Registered User
Join Date: Oct 2014
Location: California Central Coast
Posts: 1,476
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Let's try this one. Cracked cylinder/head #4/5 ? resulting in coolant in the oil. Oil filter is downstream of the oil pump so sees pressure not vacuum. Coolant saturated the paper filter media which swelled closed causing high DP across the media resulting in element collapse. Excessive vapor from coolant in the crankcase overwhelmed the AOS resulting in failure.
Last edited by 911monty; 04-27-2018 at 04:49 PM.
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04-27-2018, 05:23 PM
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#1052
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Quote:
Originally Posted by seningen
I'm thinking that's the case -- was there any smoke out the back?
Mike
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No smoke at all.
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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05-01-2018, 09:53 AM
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#1053
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Replacement engine installed! Used engine runs great. I'll put some miles on it today and maybe run it on the dyno tomorrow...
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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05-01-2018, 12:31 PM
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#1054
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Registered User
Join Date: Jun 2016
Location: Arizona
Posts: 379
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Quote:
Originally Posted by 911monty
Let's try this one. Cracked cylinder/head #4/5 ? resulting in coolant in the oil. Oil filter is downstream of the oil pump so sees pressure not vacuum. Coolant saturated the paper filter media which swelled closed causing high DP across the media resulting in element collapse. Excessive vapor from coolant in the crankcase overwhelmed the AOS resulting in failure.
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Failure mode #???
Yeah was going to say filter is post pump. I can’t think of another way that the oil filter collapsed other than it absorbed coolant/water. These are not designed for separating water. Maybe a synthetic media filter would have done better? I.E. spin on.
The other question is: did the coolant in oil make the AOS fail? Funny that there was no smoke but there was a ton of oil in the intake...
I’m thinking more and more that the AOS didn’t fail, that is was just oil starvation caused by the crushed filter, destroyed / spun bearing somewhere?
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2002 Boxster S - NHP 200 Cell Headers,test pipes,Borla CatBack,Competition Plenum,74 mm TB, EVOMS Tune,Tarett UDP,Eibach Swaybars,BIlstein PSS9s,TuneRS rear toe links,wheel studs,15 mm wheel spacers on all 4,EBC yellow stuff pads,Sebro rotors, EBS oil baffles,160 deg Thermostat,2 quart Accusump,full filtration remote oil filter,rad fan switch,custom gauge/switch plate, Race Capture data logging, 90K miles
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05-01-2018, 08:22 PM
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#1055
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Track rat
Join Date: Nov 2006
Location: Southern ID
Posts: 3,701
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I'm guessing failure of the engine oil cooler or an internal freeze plug causing intermix> collapsed filter> blown AOS> Oil in the intake. The motor is full of goo but if no metal debris it may be salvageable.
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2009 Cayman 2.9L PDK (with a few tweaks)
PCA-GPX Chief Driving Instructor-Ret.
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05-01-2018, 09:37 PM
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#1056
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Quote:
Originally Posted by AZ986S
Failure mode #???
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I'm having the old engine moved to my house and will do a tear down. Stay tuned...
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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05-01-2018, 09:43 PM
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#1057
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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Quote:
Originally Posted by thstone
Replacement engine installed! Used engine runs great. I'll put some miles on it today and maybe run it on the dyno tomorrow...
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I drove the car about 60 miles around LA's freeway's today (mid-day to avoid traffic!). Had the opportunity to do a few 0-80mph runs while shifting at redline on the 110 Frwy north of downtown LA where the freeway on-ramps are about one car length. Engine seemed to have good (normal) power and ran perfect.
The only thing that I noticed was that the water temp was a little higher than it used to be - and then I remembered that I forgot to have the shop swap over the low temp thermostat from the old engine to the replacement. Guess what I'm doing this weekend? (might even replace the water pump while I'm in there).
Off to the dyno tomorrow...
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
Last edited by thstone; 05-01-2018 at 09:48 PM.
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05-06-2018, 09:05 AM
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#1058
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Certified Boxster Addict
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,669
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The dyno wasn't available last week so I decided to just go to Willow Springs on Friday to test. I did 4 x 30 mins sessions and the engine ran perfect. It was easy to do 1:35 lap times on a fairly warm day. I'll try to get onto the dyno this week just so I know where this engine stands in terms of power.
The most interesting thing about an open test day is some of the other cars that show up...
Like this LeMon's Flying Pig car...
Or this BMW spewing fuel from the right rear corner on every left hand turn...
__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor
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05-06-2018, 10:59 PM
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#1059
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Registered User
Join Date: Feb 2017
Location: CO
Posts: 989
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Quote:
Originally Posted by thstone
The dyno wasn't available last week so I decided to just go to Willow Springs on Friday to test. I did 4 x 30 mins sessions and the engine ran perfect. It was easy to do 1:35 lap times on a fairly warm day. I'll try to get onto the dyno this week just so I know where this engine stands in terms of power.
The most interesting thing about an open test day is some of the other cars that show up...
Like this LeMon's Flying Pig car...
Or this BMW spewing fuel from the right rear corner on every left hand turn...
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Wow... 
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05-14-2018, 10:10 PM
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#1060
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Registered User
Join Date: Jun 2014
Location: LB, Germany
Posts: 1,507
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Some news what caused the engine failure? Oil filter looks pretty trashed. What brand was it?
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1998 Porsche Boxster
Lil Red
2009 Porsche Cayman 2.9L
Linear Mode
