IMS failure???

[sepesusi63]

Thanks for the guidance guys. Really appreciated.
I will let the tears try first , and make a plan then how to proceed.
We are heading towards autumn/winter time in Finland anyway. Plan was to keep the Boxster in my garage over winter period anyway. Now the winter break just unfortunately started bit too early....

But honestly speaking I am that much of an engineer, that I will need to open up the damaged engine just to check what is wrong with it, and if I can fix it myself....

Found already some interesting refurbished replacement engines from ebay.co.uk.
With reasonable prices....

So lets see what will happen.

[78F350]

Just cover the hole with some JB-Weld epoxy and run it for the rest of the sunny season. What do you have to lose...

(Just kidding)

If you do take on the job of rebuilding it There's lots of info here and elsewhere along with some good videos. I learned quite a bit by just taking apart my bad engine.
This thread is good reading if you haven't already seen it:
my DIY engine rebuild

[sepesusi63]

Just update those who might be interested.
I have finally teared the engine into pieces after few months sorrow time…
As assumed, original problem was failed IMS-bearing causing main chain (between crankshaft and intermediate shaft) tension blade to break (see enclosed pictures). Loose piece of the tension blade went in between IMS sprocket and engine block punching a hole in the block as sown before.
Had some luck also, since even timing had slipped on both cylinder blocks, and all exhaust valves had touched piston heads, there was only one visually bent exhaust valve. Took the cylinder heads to local workshop for checking, and they discovered that totally 5 exhaust valves need to be replaced. But not so bad (only 5 out of 12) what it could have been.
Decided to replace all moving parts inside the engine since it is in pieces. So I have ordered: both cam chains, main chain, all support and tension blades for the chains, main bearings for crank shaft, piston rod bearings, all AOS units (3 pieces), pressure bearing for clutch, ceramic IMS-bearing, full set of gaskets, etc.
Have already sent about 2800 EUR for the parts. I could have done it cheaper of course, by replacing necessary part only, but on the other hand now it will be equal to new engine (more or less) and since it was in pieces…
Still cheaper option than replacement engine. I checked prices for replacement engines as well. Engine from collision car with only 3 months warranty, driven about 100 tkm, was about 3400 EUR + new IMS-bearing = 4000 EUR. Rebuild engine with new piston rings, bearing, AOS, etc. with 1 year warranty was about 5500 EUR (old engine needed for exchange).
Hole in the engine block was welded in one of the local workshops. Went actually quite smoothly and looks good.
Been washing and cleaning the engine parts while been waiting for the ordered parts. For example most of the hydraulic lifters (or tappets) were jammed. So I needed to dismantle (not an easy task…) them and clean them properly. I hoped that I have not saved in wrong place with the hydraulic lifters??? I mean not replacing them???
Been manufacturing some special tools myself, and still need to some for piston installation. So far I have not purchased any special tools, but some normal ones available in local tools shop.
I have also bought quite many instruction books and work shop manuals.
Been very interesting project. I still have a goal to get it done before 1st of May (that is normally when the summer or spring at least starts here in Finland). I took me about one month to remove the engine from the car and dismantle it (working evening and weekends) so I am assuming that it will take maybe about two months to put it back together (more time needed for reading instructions and checking things).
So wish me luck and Happy New year to all of You 
PS. I have a lot of pictures available of the project if somebody is interested to see them.

[thstone]

Originally Posted by sepesusi63

For example most of the hydraulic lifters (or tappets) were jammed. So I needed to dismantle (not an easy task…) them and clean them properly. I hoped that I have not saved in wrong place with the hydraulic lifters??? I mean not replacing them???

All of the lifters and the lifter carrier should be replaced if you want 100% reliability - especially if there was enough debris in the oil to cause the lifters to jam up.

While it is common to clean them up/re-use and take your chances, this practice is what caused my repeat engine failure after a full rebuild when the used lifters and used lifter carrier failed within several hundred miles after the rebuild.

Best of luck with the rebuild and keep us up to date on your progress!

[rexcramer]

Well done sir, for taking this project on. I/We look forward to learning from your experience. I have had 6 or 7 mid 60's VW engines in pieces in my lap before, but I am not sure about these engines. Please keep us in the loop, as you can.

What has been your biggest struggle/challenge so far?

How close to scrapping the car did you get? Or were you always going to fix it?

Best of Luck and of the New Year

[sepesusi63]

Originally Posted by rexcramer

Well done sir, for taking this project on. I/We look forward to learning from your experience. I have had 6 or 7 mid 60's VW engines in pieces in my lap before, but I am not sure about these engines. Please keep us in the loop, as you can.

What has been your biggest struggle/challenge so far?

How close to scrapping the car did you get? Or were you always going to fix it?

Best of Luck and of the New Year

Thanks for your interest and support

There has not been that difficult parts work wise (not so far), but it has been more difficult to decide in where to draw the line, meaning what parts to replace and what to use from old.

Looking for correct work shop manuals and instruction has not been that easy either.

For sure there will be some challenge when I will start to put it together again, but we take them as they come

Scrapping the car was never real option, although seriously considered
But replacement engine was a serious one.
Main reason being, that I just managed to enjoy the car for 2 months before it broke down.... (bought is end of May and it broke down beginning of August)

Honestly speaking, I have never rebuilt Porsche engine before. Motorcycle engines alone and some smalled car engines together with my father.
But they are man made machines not created by God, so common sense will take you far

[sepesusi63]

I can not think what could be wrong with the lifters if I have teared them in pieces (really all parts apart) and cleaned them properly with diesel oil first and then with ultrasound washer.
After that I have sinked them into motor oil. They will be stored in there until I will assembly them again.
But if there is any doubt that I should replace them, then I will do it for sure?
Additional cost will be only about 10 EUR / pc, so 240 EUR totally.

[sepesusi63]

Originally Posted by thstone

All of the lifters and the lifter carrier should be replaced if you want 100% reliability - especially if there was enough debris in the oil to cause the lifters to jam up.

While it is common to clean them up/re-use and take your chances, this practice is what caused my repeat engine failure after a full rebuild when the used lifters and used lifter carrier failed within several hundred miles after the rebuild.

Best of luck with the rebuild and keep us up to date on your progress!

I am still thinkin about the hydraulic lifters. There was no metallic particles inside when I opened them. Just old tar type of oil...

Don't know if that was the reason why they had jammed?

Read also from somewhere that there has been some type fault in the original lifters (part no 996 105 041 50) and therefore they have been replacesed with new model (part no 996.... 72).

So I am just wondering if cleaning will do the job, or if I have to seriously concider replacement???