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Old 01-16-2021, 07:05 PM   #1
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So... I have this spare engine.

My 2000 Boxster is running fine but the cam deviations are limit so I was thinking about dropping the engine to change the cam chain pads and check the IMSB and replace necessary clutch parts at the same time. Unfortunately this would mean the car would be off the road for a good part of the driving season (which for me is April to November, if I'm lucky, here in Quebec). I know how slow I am at getting projects done so started thinking about buying an engine that I could check over then install in the car and take my time to do the necessary stuff to the original engine.
So in Juin 2020 I found what looked like a good deal on an engine out of a wrecked 2000 and I bought it... thinking that the border would be open again relatively quickly. Well, I was finally able to get it delivered to my garage in mid December... long story, with a happy ending.
Now with the engine on my engine stand I have started checking it out. First impression is positive i.e. it doesn't look like a piece of scrap. It is supposed to have just under 100K miles on it (my original engine has about 87K miles).
So far I have...
- removed the clutch and flywheel - minimum wear and so it will likely stay on the engine.
- removed and verified the water pump - looks good, no looseness in the bearing and the impeller is pristine.
- removed the IMSB flange and checked the bearing after removing the bearing's seal ... it looks fine, no play and it is a double row. I plan to have a closer look but at this point I am planning to put a new o-ring on the flange and button it up.
- removed and cut open the oil filter - super clean, no metal or plastic worth mentioning.
I have not as yet inspected the cylinders with my borescope, that's next on the list.
I have been going back and forth on whether to dive deeper, like changing the cam chain pads before installing it in the car, but the general condition of the engine and especially the lack of plastic in the filter has my leaning toward installing it as is as long as the cylinders look OK.



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Green 2000 Boxster 5-speed
1978 928 auto
1987 924S 5-speed (Sold)
Blue 2000 Boxster 5-speed (Sold)
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Old 01-17-2021, 05:20 AM   #2
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Quote:
Originally Posted by elgyqc View Post
My 2000 Boxster is running fine but the cam deviations are limit so I was thinking about dropping the engine to change the cam chain pads and check the IMSB and replace necessary clutch parts at the same time. Unfortunately this would mean the car would be off the road for a good part of the driving season (which for me is April to November, if I'm lucky, here in Quebec). I know how slow I am at getting projects done so started thinking about buying an engine that I could check over then install in the car and take my time to do the necessary stuff to the original engine.
So in Juin 2020 I found what looked like a good deal on an engine out of a wrecked 2000 and I bought it... thinking that the border would be open again relatively quickly. Well, I was finally able to get it delivered to my garage in mid December... long story, with a happy ending.
Now with the engine on my engine stand I have started checking it out. First impression is positive i.e. it doesn't look like a piece of scrap. It is supposed to have just under 100K miles on it (my original engine has about 87K miles).
So far I have...
- removed the clutch and flywheel - minimum wear and so it will likely stay on the engine.
- removed and verified the water pump - looks good, no looseness in the bearing and the impeller is pristine.
- removed the IMSB flange and checked the bearing after removing the bearing's seal ... it looks fine, no play and it is a double row. I plan to have a closer look but at this point I am planning to put a new o-ring on the flange and button it up.
- removed and cut open the oil filter - super clean, no metal or plastic worth mentioning.
I have not as yet inspected the cylinders with my borescope, that's next on the list.
I have been going back and forth on whether to dive deeper, like changing the cam chain pads before installing it in the car, but the general condition of the engine and especially the lack of plastic in the filter has my leaning toward installing it as is as long as the cylinders look OK.

Personally, after inspecting with the scope, I would install it and drive it like you have a spare. Put the funds into the original and take your time. Build it the way you want. Good luck.
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Old 01-17-2021, 08:00 AM   #3
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Totally with Dllrd23--run it!
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Old 01-21-2021, 04:46 PM   #4
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Here is the IMSB with the outer seal removed, closer inspection has not turned up any anomalies so it is staying put.



I inspected the cylinders with my borescope and all looks good.
The spark plug tubes are not leaking... so I assume the orings have been changed at some point.
Checked the accessories and pulleys at the front of the engine and all turn easily with no looseness. I think I will leave the alternator, power steering pump and starter that came on the engine rather than transferring over those that are on the engine that is in the car.

I have pretty well decided to install the engine as is and run it this summer while working on the original engine.

I have ordered a new AOS, pilot bearing for the flywheel and a clutch throwout bearing as well as a new engine mount and various gaskets and fasteners.

Here is the engine mount that came with the engine... the mount currently in the car is also shot.

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Green 2000 Boxster 5-speed
1978 928 auto
1987 924S 5-speed (Sold)
Blue 2000 Boxster 5-speed (Sold)
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Old 01-23-2021, 08:26 AM   #5
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Duck tape'll fix that mount in no time!
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Old 02-20-2021, 12:10 PM   #6
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The engine is ready to go into the car... I have to wait till the snow melts and I can move my 928 out and put the Boxster in the garage. Some additional things that I have done.
- removed the alternator - it seems to be a bit noisy when I spin it by hand, I was thinking of changing the bearing(s) but decided to wait till the other engine is out of the car and I will install the best one of the two.
- greased the starter.
- cleaned up the coils and put JB weld on the small cracks. Newart gave me a box of used coils and I chose the nicest ones from the engine and those he contributed.
- had to safety wire one coil connection given that the wiring harness connector clip was broken. I will try and get a new connector sometime.



- installed a new AOS
- reinstalled the water pump with a new gasket. The pump has a plastic impeller and looks like new. But it looks like there has been a water pump with a metal impeller in this engine's past - there is a wear spot in the cavity...



- installed my rebuilt engine mount with my homemade rubber stops...
(DIY Engine Mount Stop - 9A137525701 ?)
- checked the wiring harness for damaged wires.
- cleaned up the clutch and flywheel and installed a new pilot bearing.
- drilled out 3 broken exhaust header bolts and installed helicoils (the bolts were broken when I received the engine).

I am slightly intimidated by the engine switch, but Newart has offered to help and he has already BTDT. The other problem is when spring arrives I plan to drive the car a bit before putting it in the garage... and I may have a problem convincing myself that I can live without it for a couple of weeks... well that will be an incentive to get the 928 running properly...

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Green 2000 Boxster 5-speed
1978 928 auto
1987 924S 5-speed (Sold)
Blue 2000 Boxster 5-speed (Sold)

Last edited by elgyqc; 02-20-2021 at 02:00 PM. Reason: addition of text
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