IMS Replacement... The Jager Saga

[Jager]

986 Forum team,
I’m not sure how many pictures I can add in a single post, or how many pictures can be put on a thread, most likely I will find out the hard way. If you’re like me I really enjoy looking at the pictures from others on this site. I would like to share my project with the forum; hopefully a few folks will cheer me on while others will give me a hard time, and yet I know others will help if I run into problems. Brucelee please don’t get too upset if I use-up all the hard drive space on the server. : 0

A post from a well know member of this forum a few weeks ago, in response to a question I had on, “what’s the highest mileage you have seen on a Boxster?” (BTW I have over 210,000 miles on my car now) got me out of my chair to dust-off the old torque wrenches. My 2001 Boxster has been a great car, the best car I have ever owned, but I was reminded, indirectly, that I should take care of a known possible issue, and not to ignore its faithful wearing of parts.

While digging deep into the guts of my 986 I will replace the flywheel, clutch, rear main seal, O2 sensors, and motor mount.

[Jager]

I like these eye protectors.

[Jager]

Uncovered the motor...

[Jager]

Drained the oil and replaced plug with LN Engineering (Bigfoot) magnetic plug. Notice the socket size difference between new LN Engineering plug (on the left) and the original plug, 10mm versus 8mm.

[Jager]

Dropped the pan and found about 10 pounds of dirt and gravel. I had to use a shovel to find the top surface of the pan.

[Jager]

30 minutes later after using wheel cleaner and a brush.

[Jager]

Might replace this someday, but not on this project.

[Jager]

Transmission is next

[Jager]

I don’t think I have ever done a double take while working under a car but WTF is this? I don’t have that tool! A 10mm triple square near the bottom of the transmission on the driver’s side.. I did not catch this in the instructions. Dang it, now I had to find this socket.

Not a single store in town had triple square bits/sockets. So I called Snap On to see if he was coming my way today… Yes!

Now that I have a full set of triple square sockets/bits I was ready to hit it again.

[Jager]

Transmission is down, clutch and flywheel removed. Almost down to the rivets on the clutch plate.

[Jager]

Looks like a single row IMS bearing. Maybe with this RMS leak it was providing the IMS bearing additional lubrication. : )

[Jager]

Locked the crank at TDC.

[Jager]

Locked the cam.

[Jager]

Removing the RMS… This was easy; drilled a couple of holes and installed screws. I didn’t have to pull on the screw on the left side, probably because of the mileage on this seal.

[WhipE350]

I enjoyed the posts! Use .jpg and Bruce's server won't be so full I assume there is more to come.

[Jager]

Installing new RMS… I used a plastic pipe cap from the local hardware store plumbing department. This plastic cap worked great and was a lot less expensive than the Porsche tool for this job.

[Jager]

Originally Posted by WhipE350

I enjoyed the posts! Use .jpg and Bruce's server won't be so full I assume there is more to come.

Yep, more to come. I will see how jpg look.

[Jager]

Time to remove the chain tensioners and IMS bearing... This bearing was getting lots of oil.

[Jager]

For added security, to help prevent the IMS shaft from moving, I inserted set screws. I didn’t tighten these too much.

[Jager]

Removed the bearing clip.