Engine Removal, Rebuild, and Re-installaion

[dbergondy]

Your project looks good (just saw your 12/23 post)!

I have a 2001 Boxster S with IMS failure ... trying to figure out what I should do!

Thanks for all of the pictures and information.

[woodsman]

I too am enjoying the great pics!

[Jamesp]

More progress made now that I can take a little time off work.



Two things I would do differently are 1) Take many more pictures. I took maybe 50 during disassembly, 3 times that amount would have been better. Wide shots of the whole engine from every possible angle, and close ups of everything before it is taken apart. 2) More blue tape - I labeled every bolt and put them into ziplocks for each item removed and labeled the items for general assembly, but I did not label every connector in the wiring harness. I'd strongly recommend doing that for assembly. I finally figured it out but took a most of an afternoon to do it. I also tried to cheap out and reuse the brittle plastic vacuum balance tube. Crack! Pelican Parts, here I come. :ah:

After receiving and replacing a few items over the next few days, it will be time to put the engine back in the car.

Here are "before" pictures



Note the oil on the manifold under the power steering pump and all over everything else in that area



I intend to post pictures of the installation as well.

[Jamesp]

Originally Posted by dbergondy

Your project looks good (just saw your 12/23 post)!

I have a 2001 Boxster S with IMS failure ... trying to figure out what I should do!

Thanks for all of the pictures and information.

I've learned a lot in this process - The members in this forum have been great and I appreciate all the advice and knowledge they gave to me. If you have the time, space and money to rebuild the engine, it is worthwhile if you have that interest. I drew the line of rebuilding at whether or not the valves hit the pistons. If the valves contacted the pistons it would be time for a different engine. I would make that same decision today.

[Jake Raby]

Congrats!
You accomplished something that many professionals are afraid of, and even more try and fail.

I would think that after this accomplishment you have a new found respect for what it takes to work with these engines at an in depth level everyday.

Love to see people tackle issues and win!

[Jamesp]

So after chasing down and correcting a wiring error and a related missing standoff / clamp, the clutch alignment tool ordered over a week ago, with two day shipping, finally arrived. It says "Ford 03" on it, what a surprise. Additional progress has been made:



I'll be installing the engine in the coming days. I have identified 18 connections between the car and the engine and made a checklist. after I have verified it, I'll post it for future reference.

[Jamesp]

Engine has beem installed in the car, cranked, failed to start, members of this forum identified a valve timing issue, engine removed, retimed, and who knows, maybe it will start when it is installed again. I've learned a lot, and if this motor fails, a 911 motor goes in, or maybe I branch out to an LS1. The main thing is to keep on learning.

[Jamesp]

It's alive!!!! bu wa! ha! ha! ha! ha!!!!, Got the engine re-installed and cranked it up. Cranked and idled smoothly at first, then the idle fell off and got thready, a little gas to keep it going and then 3 bangs and I shut it down quick. I was sure that was curtains and the CEL came on. It threw an O2 sensor low voltage, a "random misfire" and misfires from both sides of the engine. Nothing ventured, nothing gained, I fired it back up. Much less drama this time. It was still searching for idle, and all the oily hand prints were buring off the engine. So I shut it down and cleared the codes. It fired right back up again and I let it get warm at idle, took it to 2000 rpm (very smooth) then back to idle for a bit, 2500 rpm then idle for a bit, 3000 rpm, then idle all smooth. Idle was much improved but not perfect. Gauges seemed proper, no warning lights and no more CEL. BUT, when I put it in gear, and let the clutch out, it made a noise like clashing gear teeth. My thought was it sounded like the flywheel just touching the starter gear. It did that twice and then quit. Ideas?

[PhilNZ]

"When I put it in gear, and let the clutch out, it made a noise like clashing gear teeth. My thought was it sounded like the flywheel just touching the starter gear. It did that twice and then quit. Ideas?[/QUOTE]

Just to clarify. Gearbox can be engaged/disengaged ok, all gears are selectable with engine running and clutch in, but when clutch out bad noise and no drive to wheels?