Bought a 2000 Boxster S project. - 986 Forum - The Community for Porsche Boxster & Cayman Owners

elgyqc · 12-29-2022, 01:23 PM

Got back to work on the replacement engine. The new chain tensioner pads are installed in bank 1 and the oil filler tube is on the engine (the original was broken off when I got the engine)... installing it with the intake manifold in place was a challenge, I had to take the AOS to get working room. The AOS should be replaced anyway.
Got the cams off bank 2 and found this on the cam cover...

Was this to prevent oil leaking with old o-rings, I wonder. I had to beat the tubes out with my rubber hammer... but oil had been leaking despite this.

And... sealant overflow, that channel is supposed to be open or there can be oil return problems according to Jake Raby. This is the sealant that I found in the oil pickup screen.

I found another missing electrical connector, for an O2 sensor if I remember correctly. This time the wire was cut, not ripped out. I have been able to figure out what the connectors are, which is not evident given that they are not in the parts Katalog. The local Porsche parts department couldn't help beyonds saying that they are VW parts. I have ordered replacements for 2 of them. The third one is a Mercedes part number so I will have to visit the dealer... or see if I can find one at a scrap yard.

pilot4fn · 12-29-2022, 08:28 PM

Quote:

Originally Posted by elgyqc

I found another missing electrical connector, for an O2 sensor if I remember correctly. This time the wire was cut, not ripped out. I have been able to figure out what the connectors are, which is not evident given that they are not in the parts Katalog. The local Porsche parts department couldn't help beyonds saying that they are VW parts. I have ordered replacements for 2 of them. The third one is a Mercedes part number so I will have to visit the dealer... or see if I can find one at a scrap yard.

Here's link to the info what I used for new O2 sensor wireing and connectors that are working real well:
http://986forum.com/forums/boxster-general-discussions/78147-02-sensor-wire-question-header-hi-flow-cat-install.html#post619783

nuvolari · 01-01-2023, 11:40 AM

Quote:

Originally Posted by elgyqc

Got back to work on the replacement engine. The new chain tensioner pads are installed in bank 1 and the oil filler tube is on the engine (the original was broken off when I got the engine)... installing it with the intake manifold in place was a challenge, I had to take the AOS to get working room. The AOS should be replaced anyway.
Got the cams off bank 2 and found this on the cam cover...

Was this to prevent oil leaking with old o-rings, I wonder. I had to beat the tubes out with my rubber hammer... but oil had been leaking despite this.

And... sealant overflow, that channel is supposed to be open or there can be oil return problems according to Jake Raby. This is the sealant that I found in the oil pickup screen.

I found another missing electrical connector, for an O2 sensor if I remember correctly. This time the wire was cut, not ripped out. I have been able to figure out what the connectors are, which is not evident given that they are not in the parts Katalog. The local Porsche parts department couldn't help beyonds saying that they are VW parts. I have ordered replacements for 2 of them. The third one is a Mercedes part number so I will have to visit the dealer... or see if I can find one at a scrap yard.

So I'm going to check out a 2003 at the local pick a part. If you can let me know exactly which connectors you need, I'd be happy to snip them off the car provided I can get to them. Just send me a list with what they are and maybe pics and where they are located and/or part numbers. I'll send them to you for whatever they charge me and shipping. Just be aware I will cut the wires with a few inches of wire unless there is a way to get it without cutting which there usually isn't so you will have to splice them into your harness.
Let me know ASAP.

elgyqc · 01-02-2023, 08:04 AM

Quote:

Originally Posted by nuvolari

So I'm going to check out a 2003 at the local pick a part. If you can let me know exactly which connectors you need, I'd be happy to snip them off the car provided I can get to them. Just send me a list with what they are and maybe pics and where they are located and/or part numbers. I'll send them to you for whatever they charge me and shipping. Just be aware I will cut the wires with a few inches of wire unless there is a way to get it without cutting which there usually isn't so you will have to splice them into your harness.
Let me know ASAP.

Thanks for the offer. If it doesn't work out or they want crazy money no problem I think I have alternate sources. The pictures of the unbroken connectors are from another engine I have.
Connector 1 on right side of the engine, exits the wiring harness between 2nd and 3rd legs of the intake manifold and goes to the secondary air pump (or the engine fan)

Connector 2 on right side of the engine, exits the wiring harness between near the first leg of the intake manifold and goes to the engine fan (or the secondary air pump)

Connector 3 on left side of the engine, goes between the wires and the bracket on the valve cover. There is also one on the right side of the engine which might be easier if your are already in there for the other connectors.

Thanks in advance.

nuvolari · 01-02-2023, 01:12 PM

Quote:

Originally Posted by elgyqc

Thanks for the offer. If it doesn't work out or they want crazy money no problem I think I have alternate sources. The pictures of the unbroken connectors are from another engine I have.
Connector 1 on right side of the engine, exits the wiring harness between 2nd and 3rd legs of the intake manifold and goes to the secondary air pump (or the engine fan)

Connector 2 on right side of the engine, exits the wiring harness between near the first leg of the intake manifold and goes to the engine fan (or the secondary air pump)

Connector 3 on left side of the engine, goes between the wires and the bracket on the valve cover. There is also one on the right side of the engine which might be easier if your are already in there for the other connectors.

Thanks in advance.

Ok, it might take a few days as it's been raining here a lot. Your explanation of parts needed is very good except I'm not sure what Connector 3 connects? You say from the harness to the "bracket on the cylinder head" but I'm not sure what you mean exactly. Is it for the cam position sensor?

And ha on the connectors 1 and 2 as those are the same ones I ripped off when lowering my engine. But don't worry as I've already located some for my car. Hell, I might just start grabbing these on every junkyard car from now on since they are easy to forget.

Also, I posted a thread awhile ago in Rennlist forum about getting into the engine bay from the top when I find a car in the junkyard and you posted about getting the car into service mode manually. Did you mean with no battery power at all? Someone else posted how to jump the relay but I would still need some kind of power. I wonder what cheap and easy to carry battery might be available for this purpose. Maybe a rechrargeable power tool battery? Does anyone know? If so, please DM me or post in this Rennlist thread:

https://rennlist.com/forums/boxster-and-boxster-s-986-forum/1281523-boxster-at-pick-a-part-how-do-i-put-it-in-service-mode-with-no-battery.html

elgyqc · 01-03-2023, 05:49 AM

Quote:

Originally Posted by nuvolari

... I'm not sure what Connector 3 connects? You say from the harness to the "bracket on the cylinder head" but I'm not sure what you mean exactly. Is it for the cam position sensor?

It is for the O2 sensor as I remember it. The wire that I need exits the wiring harness and goes to the bracket that is bolted to the cam cover where it is connected to the wire that comes up from the O2 sensor in the exhaust system.

Quote:

Originally Posted by nuvolari

Also, I posted a thread awhile ago in Rennlist forum about getting into the engine bay from the top when I find a car in the junkyard and you posted about getting the car into service mode manually. Did you mean with no battery power at all? Someone else posted how to jump the relay but I would still need some kind of power. I wonder what cheap and easy to carry battery might be available for this purpose. Maybe a rechargeable power tool battery? Does anyone know? If so, please DM me or post in this Rennlist thread:

https://rennlist.com/forums/boxster-and-boxster-s-986-forum/1281523-boxster-at-pick-a-part-how-do-i-put-it-in-service-mode-with-no-battery.html

I posted the relevant owner's manual pages to the above thread.

nuvolari · 01-03-2023, 11:44 PM

Quote:

Originally Posted by elgyqc

It is for the O2 sensor as I remember it. The wire that I need exits the wiring harness and goes to the bracket that is bolted to the cam cover where it is connected to the wire that comes up from the O2 sensor in the exhaust system.

I posted the relevant owner's manual pages to the above thread.

Got it. Stand by....

Homeoboxter · 03-12-2023, 06:47 PM

I like that you attempt to fix everything that most of us would just toss and replace. Hope it`s gonna hold

elgyqc · 03-13-2023, 05:40 AM

Quote:

Originally Posted by Homeoboxter

I like that you attempt to fix everything that most of us would just toss and replace. Hope it`s gonna hold

Thanks, it's half because I don't have money to throw away and half because I don't like to waste things that can be fixed... and an extra half because I enjoy the challenge.
My only worry with the reservoir is that the plastic is so old it will fail somewhere else, like the fitting for the vacuum line that looks a bit fragile. But now that I know what I am doing I could remove the reservoir with the engine in the car, although it would be a big PITA.

Gilles · 01-04-2023, 11:48 AM

Quote:

Originally Posted by nuvolari

Ok, it might take a few days as it's been raining here a lot.
Someone else posted how to jump the relay but I would still need some kind of power. I wonder what cheap and easy to carry battery might be available for this purpose. Maybe a rechrargeable power tool battery? Does anyone know? If so, please DM me or post in this Rennlist thread:

Not kidding about the rain and it seems that we have a lot more on the way (thankfully as we had been on a draught for many, many years)..

Regarding the battery (or power source), I saw in Costco a small (rechargeable) battery pack that claims to be able to jump start a car a few times it looks very portable (size of a book) and I am very tempted to buy one to take on my junkyard trips as many times you cannot determine the mileage of a car or to check if an electric component works or not before removing it, someone here may have one and hopefully share their comments.
.

Homeoboxter · 01-04-2023, 01:23 PM

Quote:

Originally Posted by Gilles

Not kidding about the rain and it seems that we have a lot more on the way (thankfully as we had been on a draught for many, many years)..

Regarding the battery (or power source), I saw in Costco a small (rechargeable) battery pack that claims to be able to jump start a car a few times it looks very portable (size of a book) and I am very tempted to buy one to take on my junkyard trips as many times you cannot determine the mileage of a car or to check if an electric component works or not before removing it, someone here may have one and hopefully share their comments.
.

Once I needed to pull a power seat from a car at a Pick ur Part and I asked them if I can bring the battery from my car to power the seat so I can move it to get access to the bolts. They said that`s not allowed bc it`s a fire hazard

I think you can smuggle a small battery in though, or you can assemble a battery pack using 8 AA batteries for instance. Or connect wires to your power tool and use its battery as a power source.

nuvolari · 01-06-2023, 10:31 AM

Quote:

Originally Posted by Homeoboxter

Once I needed to pull a power seat from a car at a Pick ur Part and I asked them if I can bring the battery from my car to power the seat so I can move it to get access to the bolts. They said that`s not allowed bc it`s a fire hazard

I think you can smuggle a small battery in though, or you can assemble a battery pack using 8 AA batteries for instance. Or connect wires to your power tool and use its battery as a power source.

I was considering the AA battery pack but wasn't sure if it would be strong enough to run the top motor so I figured a sawzall battery might be better. Plus, it's always fun to have a sawzall in the junkyard.

And the rain has finally lifted so I'm off the junkyard....