Blue boxster resurrection project - 986 Forum - The Community for Porsche Boxster & Cayman Owners

Homeoboxter · 11-27-2018, 08:26 PM

Hey Folks,

I bought this `99 Boxster a few months ago with an engine suffering from an alleged catastrophic engine failure. I have literally zero experience with Porsches, so I thought it`s time to delve into this new challenge with the intention to fix the unsalvagable engine on my own. This is a low-budget project, and it`s not urgent as I don`t really need the car soon, in fact, I just bought it for fun. Anyway, I made some progress with the engine during which I made a bunch of pictures so I can remember where to put the parts back on. I thought I would share some of these pics in this thread and keep uploading more as the project goes on.

So, here`s the thing on the day I hauled it home:

It has a few dents and scratches here and there due to the storage. It`s been sitting in a garage for 11 years and has 100k miles in the meter.

Jacked up for engine removal:

To be continued..

redciv1 · 11-28-2018, 04:24 AM

...and so it begins!!!

RedTele58 · 11-28-2018, 08:45 AM

Cool! I'm in. Beautiful car.

Homeoboxter · 11-28-2018, 10:11 AM

Quote:

Originally Posted by RedTele58

Cool! I'm in. Beautiful car.

Thanks, if you look at it from far enough it seems immaculate

It`s a pity it got scratched and dented during storage. I plan to to something to that large dent on the right fender at least.

RedTele58 · 11-28-2018, 12:22 PM

Quote:

Originally Posted by Homeoboxter

Thanks, if you look at it from far enough it seems immaculate

It`s a pity it got scratched and dented during storage. I plan to to something to that large dent on the right fender at least.

It's on the top of the fender behind the headlight? You'd be amazed what a good paintless dent repair guy can do. For the scratches - get on Youtube and look around at some of the detail guys - Ammo NYC particularly. He does amazing work on original paint. Check his website out for his products.

I get a lot of satisfaction from bringing a dead Boxster back to life. It might not be the cheapest thing to do, but it's a very satisfying hobby.

If you run into problems, just ask the guys here on the board. There are a lot of smart guys that really know these cars.

Burg Boxster · 11-28-2018, 01:19 PM

Heck I'd be tempted to give that one a try myself w/ some good spoons. You can access area pretty easily after you pop the headlight pod out. Otherwise I guarantee a good PDR guy can knock that out in a snap.

If you don't know a great PDR guy, ask for referral at a high end dealer. Better yet, let them make their $25-50 on the deal too (will help you in building some goodwill if ever needed) and have them schedule on his/her next trip thru. The quality PDR and PPF gurus have premium dealers on a weekly paper route of sorts...

Good luck

Quote:

Originally Posted by RedTele58

It's on the top of the fender behind the headlight? You'd be amazed what a good paintless dent repair guy can do.

Homeoboxter · 11-28-2018, 09:12 PM

Quote:

Originally Posted by Burg Boxster

Heck I'd be tempted to give that one a try myself w/ some good spoons. You can access area pretty easily after you pop the headlight pod out. Otherwise I guarantee a good PDR guy can knock that out in a snap.

If you don't know a great PDR guy, ask for referral at a high end dealer. Better yet, let them make their $25-50 on the deal too (will help you in building some goodwill if ever needed) and have them schedule on his/her next trip thru. The quality PDR and PPF gurus have premium dealers on a weekly paper route of sorts...

Good luck

Thanks! Just ordered a dent-pulling set from China, let`s see if I can make it worse!

BruceH · 11-30-2018, 05:29 AM

Thanks for the morning chuckles guys

I love the BIL observer comment! This is a great thread, thanks for taking the time to post your project

Homeoboxter · 11-30-2018, 01:35 PM

Quote:

Originally Posted by BruceH

Thanks for the morning chuckles guys

I love the BIL observer comment! This is a great thread, thanks for taking the time to post your project

Welcome to the thread, I`m glad you are enjoying it! I love to read similar posts and it`s not much effort to upload a few pics every day.

BOOTLEG · 11-30-2018, 07:41 AM

some like women, he likes Boxsters. Claims he doesn't have to buy them dinner

Homeoboxter · 11-30-2018, 01:37 PM

Quote:

Originally Posted by BOOTLEG

some like women, he likes Boxsters. Claims he doesn't have to buy them dinner

Fair point! However, feeding these cars with parts seems to be pricey too..

Homeoboxter · 12-01-2018, 07:57 AM

Fallen-off engine shot from engine compartment:

Pulling it up using an engine hoist:

Rolling out on a furniture dolly:

Finally inside the garage:

Homeoboxter · 12-01-2018, 08:24 AM

Clutch off:

Rivets were running on the pressure plate. Perhaps still the original clutch set?

RMS leak, or both RMS&IMS?

Homeoboxter · 12-02-2018, 07:37 PM

Here`s a little more progress today on stripping the engine.
Mating engine with stand:

Opossum-damage, close-ups:

Thick oil-mud on the heads:

Sophisticated method to prevent steering pump shaft from spinning:

Stripped:

We`ll take a peek into the engine next time.

Homeoboxter · 12-06-2018, 09:35 PM

Sump off. Looks clean, no sludge or metal debris. Except for those green and brown plastic fragments..

Inside everything seems intact so far.

Let`s approach now from the heads. Cylinder 4-6 first.

Scavanging pump off:

Head cover off. Something seems missing from there. Perhaps the origin of the plastic debris in the oil pan?

Not much left. The middle part, the actual rail is completely gone.

After the plastic chain guide completely had given up the chain was running on the steel bracket. May have been producing an awful sound though..

Homeoboxter · 12-06-2018, 09:42 PM

Lifters, cylinder head, liners all look fine:

Ottomotion · 12-07-2018, 09:48 AM

Looks like we are tackling similar projects...I posted mine up on the General Discussion forum. Mine is a 3 chain 03 motor though.
Just got my drivers side head back on and after the cams are back in and i button that side up, I plan on tearing down the other side.
Where in N. Cal are you?

Homeoboxter · 12-07-2018, 03:12 PM

Hey, I`m located close to San Jose. Are you nearby?

Quote:

Originally Posted by Ottomotion

Looks like we are tackling similar projects...I posted mine up on the General Discussion forum. Mine is a 3 chain 03 motor though.
Just got my drivers side head back on and after the cams are back in and i button that side up, I plan on tearing down the other side.
Where in N. Cal are you?

Ottomotion · 12-08-2018, 06:45 AM

Fresno.
Keep it up. Its nice to see someone else attempting this same task at the same time.

So if I am seeing and reading correctly, your chain guide/tensioner failed and your chain was riding on metal?
Interesting fail....My car has just over 100K on the clock and the pads look like new....
Now the valve spring and lifter for #5 intake...thats a different story.

Homeoboxter · 12-08-2018, 07:43 AM

Quote:

Originally Posted by Ottomotion

Fresno.
Keep it up. Its nice to see someone else attempting this same task at the same time.

So if I am seeing and reading correctly, your chain guide/tensioner failed and your chain was riding on metal?
Interesting fail....My car has just over 100K on the clock and the pads look like new....
Now the valve spring and lifter for #5 intake...thats a different story.

Hey, I`ll upload new pics soon. Fresno is not so far away from here, we should meet up once both cars run again

As for the engine, indeed, the primary reason for the engine failure was the excessive wear and subsequent detachment of the chain guard. I think the chain picked up a piece of the guard on the opposite side and somehow made the timing to jump. Otherwise I can`t explain why the timing was messed up and the valves touched the pistons. Failing of these guards is frequent in these engines, yours may have been replaced earlier, or the 3-chain engines have a different design? BTW, my car has 100K miles in it and I don`t think it has been taken apart.