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Old 01-15-2019, 11:02 PM   #61
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Yesterday I tackled a bit with the starter. Not that it really needed obvious attention, just if it`s out I thought I look into it.



Came apart easily. No need to replace anything, after some cleaning and regreasing everything can go back together.




Transmission gears run on needle bearings. Pretty thoughtful.



This is kind of odd, grease seems to be migrated from the gears while sitting during the 11 year long nap..



After a bit of cleaning:



Planetary gears regreased:




A 24 mm socket helps holding the brushes during reassembly.



Done.

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Old 01-16-2019, 05:22 AM   #62
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Homeo, you do nice work, my friend. I'd let you work in my garage any time. (If there were room, of course, haha)

I am usually so pressed for time to get the current project completed (either because I need the garage for another project, or I'm trying to hit a track day, or whatever) that I rarely take the time to do these types of "just because I'm holding it in my hands already" items.

Kudos you you. Patience, perseverance, attention to detail. All good skills that are too rare at my house. Haha


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Old 01-20-2019, 04:20 PM   #63
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Originally Posted by maytag View Post
Homeo, you do nice work, my friend. I'd let you work in my garage any time. (If there were room, of course, haha)

I am usually so pressed for time to get the current project completed (either because I need the garage for another project, or I'm trying to hit a track day, or whatever) that I rarely take the time to do these types of "just because I'm holding it in my hands already" items.

Kudos you you. Patience, perseverance, attention to detail. All good skills that are too rare at my house. Haha


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Thanks! I just check everything on the way as I don`t want to pull apart everything again when it turns out something failed and I missed it. This engine design doesn`t seem to allow you to fix anything easily with the engine in the car. And I have a tendency to get lost in the details that just makes all my projects last forever
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Old 01-20-2019, 04:58 PM   #64
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Ok, so I`m still stuck finding matching rings for the car. First here are some pics of the ring gap measurements I made:



I pushed down all the rings all the way to the bottom and meaured the end gaps with a feeeler gage.
Here`s the result:



I couldn`t find specifications for this particular car, but based on other German cars with similar bor size (e.g. BMW) they are way out of specs. The side rails for the 3rd rings look pretty badly worn in particular:



I`ll do proper measurements for the wear with a bore gauge once I receive it from Amazon. The bores look fine though, and I think a fresh ring set will make a big difference. Problem is, I can`t get one for the 2.5L engine. There are available aftermarket sets for the 2.7 engine, but they are listed as non-matching for the 2.5L, and I don`t really understand why, since the two cars have the same bore size (85.5mm) and the thickness of the rings seems to be the same too (1.5; 1.2; 2.0 mm):





Can someone confirm they are identical?
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Old 01-21-2019, 06:53 PM   #65
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I didn`t like the idea that the IMS is air-tight sealed and the only way for depressurization is through the bearing. Also, the engine shouldn`t allocate energy into spinning about a liter oil got caught inside a tube. So, I drilled a hole through the IMS. Here the pressure can be released and the oil that got stuck will be drained by centrifugal force.

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Old 01-26-2019, 07:17 PM   #66
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Still no progress on the engine at all, I`m waithing for the rings to arrive. Fortunately this car has many other things to tackle with so I don`t get bored. The alternator made this not too healthy squeaking noise when spinning so I decided to rebuild it. In retrospect, it wasn`t worth the time, but if all goes well I`ll have a refurbished original BOSCH alternator.







Few Philips screws hold the back panel.


Could`ve been useful to spray the bolts with WD40 or similar.. Result: one broken bolt and one with stripped head. Next time!



The two halves came apart anyway:



I can counterhold the shaft with this bit but how to get access to this silly recessed nut?



After a quick visit to the hardware store I came up with this:



Unpullied:



What a disaster..

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Old 01-26-2019, 07:38 PM   #67
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Drilling out the broken bolt:



The threads didn`t survive the removal so I drilled them through, tapped and inserted two helicoil threads in.





This is the rebuild kit I`ll throw in. Not a bad deal for $25.



I also invested into this ($8):



Works pretty well for the bearing on the back.



For the front one I needed some additional tools and I had to remove the outer race:



Leftover of the old slip ring now can come off:



Reassembly is coming soon.
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Old 01-27-2019, 09:36 AM   #68
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I love your write-ups. It makes me want to tackle those projects I’m always hesitant to start. Thanks for taking the time to document all your efforts. BTW, you must have some workshop and supply of tools!

Last edited by alynch; 01-28-2019 at 02:31 PM.
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Old 01-28-2019, 11:04 AM   #69
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I love your write-ups. It makes me want to tackle those projects Iím always hesitant to start. Thanks for talking the time to document all your efforts. BTW, you must have some workshop and supply of tools!
I`m glad you enjoy reading this project, I hope it`ll help others as well to do a similar job with fewer mistakes than I make I just work in my garage, I accumulated a bunch of tools for other projects over time and just order new ones along the way.. That`s why it`s taking so long!
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Old 02-14-2019, 08:20 PM   #70
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Hey Folks,

I haven`t posted for a while, the project has slowed down a bit. Spring is near though so I better speed up this restoration. At last I received the ring set for the engine. It`s not identical to the original but I think they should be fine.

Here they are:


The second is different from the original in design, different solution for the same function:



Top rings, old and new, side by side: no big difference in gap:



Same for the 2nd ring:



What was really worth the investment is the oil ring set: quite a bit of wear and deteroriation on the old ones. These rings were stuck in the piston groove in gunk.



After a slight hone on the bores they have to be ok.

I made some progress on pinning the IMS too. I realized that there is some chance for each of the three gears to spin on the shaft so I decided to pin all of them. Although I couldn`t see any sign of rotation of the gears with respect to the shaft, I made sure they are all aligned. The gear tooth on one side has to be in line with the gear trough on the other ( I looked at several IMS pics on the web to confirm this) :



Not only the shaft but also the gears are made of some surprisingly soft steel that`s quite easy to machine.



I tapped the holes with an M6 tap. I didn`t make the thread all the way through so the set screws will get stuck at the bottom.



Here`s how they look, the gear on the other end is pinned as well. They are not tightened down, hence they are sticking out. I`ll need some good permanent thread locker to finish it.


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Old 02-27-2019, 09:06 PM   #71
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Hey,
Last weekend I gave a light honing for the cylinders to get them ready for the new rings. I used a deglazer that`s free to rent at Autozone. Here`s a few pics of the tools and the result.







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Old 03-22-2019, 10:46 AM   #72
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I'm loving this rebuild!

Any news?
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Old 03-23-2019, 09:41 PM   #73
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I'm loving this rebuild!

Any news?
Hi, not much unfortunately, I`ve been working on my other car and didn`t get around to the Boxster. Except for the belt pulleys, they didn`t have a healthy sound so I rebuilt them fresh bearings instead of buying new ones.



A spark plug socket perfectly fits through the pulley and gets access to the bearing.





I used SKFs instead of the original FAG products.




After placing the bearings in the freezer and heating up the pulleys with a heatgun they slide right into their places after a few punches with a hammer. Make sure to use a socket that fits the external ring of the bearings.



These should be good for the next 100k miles.
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Old 04-06-2019, 04:14 AM   #74
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Just discovered this thread, I didn't even know that there was a "show-tell-gallery". You should put a link in the Performance and Technical section to share this experience.
Really impressive work!
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Old 04-09-2019, 09:11 AM   #75
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Originally Posted by elgyqc View Post
Just discovered this thread, I didn't even know that there was a "show-tell-gallery". You should put a link in the Performance and Technical section to share this experience.
Really impressive work!
Thanks! I didn`t know about the technical section
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