Blue boxster resurrection project

[BruceH]

Very nice

[Homeoboxter]

Thanks!

My engine mount was cracked so I got a new Lemforder insert and took the whole stuff to the nearest shop to get them swapped. They were willing to press it out and press the new one in for $60. I still can`t get used to the Bay Area prices. So I decided to do it myself. It was a huge pain and I spent way more time on it than it`s worth, so probably that was not the best decision, but hindsight is always 20/20.



Heating up the aluminum housing as if it made a difference.



This is my setup: I went to autozone and rented a wheel bearing puller set that I combined with my vise.



There was a great chance that I would break the vise using this meter long extension, but actually it survived.



Everything is possible, just have to force it.



I`m stronger, told you...



For assembling I was gonna save some manpower and dropped the insert in the freezer overnight and heated the housing in the oven before the action.



It helped, it was definitely easier, still a hassle though.



Time to give it some vibration

[Qingdao]

I think you are supposed to bolt that vise to a work bench... I could be wrong. LOL


I typically burn the old bushings out in this type of scenario.

[Homeoboxter]

Originally Posted by Qingdao

I think you are supposed to bolt that vise to a work bench... I could be wrong. LOL


I typically burn the old bushings out in this type of scenario.

Yeah, that vise has been like that since I moved here from my previous place... Maybe once the Porsche engine is off the bench!

If I burned out the bushing I`d end up with a steel cyilinder in an aluminum bore that I still would have to press out.

[Qingdao]

Originally Posted by Homeoboxter

Yeah, that vise has been like that since I moved here from my previous place... Maybe once the Porsche engine is off the bench!

If I burned out the bushing I`d end up with a steel cyilinder in an aluminum bore that I still would have to press out.

Ah, Why didn't you get the mount thats already in the aluminium housing? I just replaced one on a customer's car.

[Homeoboxter]

Originally Posted by Qingdao

Ah, Why didn't you get the mount thats already in the aluminium housing? I just replaced one on a customer's car.

Because it costs 5 times more than the insert only

[Homeoboxter]

There are plenty of threads here on how variocam operation can be tested with the durametric or similar diagnostic tool, but I wanted to make sure they work before putting the engine back in the car. So I used a simple borescope camera to capture the switchover of the variocam units while the engine was driven by the starter on my work bench. I inserted the camera through the hole for the green plug over the intake camshaft, on the scavanging pump side. I used 12V to switch the solenoids on. Here are some pictures, looks like they both work fine

Ths is just for guidance if it`s unclear what we are looking at:



Variocam at bank 1-3 at rest:



Variocam 1-3 actuates:



Variocam bank 4-6 at rest:



Variocam 4-6 actuates:



The video is available here, if interested:
https://www.youtube.com/watch?v=xmNduI2lRbA

[dghii]

Originally Posted by Homeoboxter

Yeah, that vise has been like that since I moved here from my previous place... Maybe once the Porsche engine is off the bench!

If I burned out the bushing I`d end up with a steel cyilinder in an aluminum bore that I still would have to press out.

For next time, mount insert removal is easy if you cut the rubber out and then use a hack saw on the remaining aluminum. saw a couple of cuts and the aluminum comes out in a couple of pieces. About 30 minutes total.

[Homeoboxter]

Originally Posted by dghii

For next time, mount insert removal is easy if you cut the rubber out and then use a hack saw on the remaining aluminum. saw a couple of cuts and the aluminum comes out in a couple of pieces. About 30 minutes total.

Thanks for the tip, but the mount insert on this car was made of steel. So was the replacement. Steel insert in an aluminum housing. I can`t see how it`s possible to cut the insert out easily without damaging the aluminum bore. Scroll back, only the core part of the mount is aluminum, then rubber, then steel. And the steel shell is pressed into the aluminum housing. Maybe there are different versions?

[pilot4fn]

Originally Posted by Homeoboxter

Thanks for the tip, but the mount insert on this car was made of steel. So was the replacement. Steel insert in an aluminum housing. I can`t see how it`s possible to cut the insert out easily without damaging the aluminum bore. Scroll back, only the core part of the mount is aluminum, then rubber, then steel. And the steel shell is pressed into the aluminum housing. Maybe there are different versions?

I had same dilemma last year. Purchased the engine mount bushing only and attempted to change it to the aluminium housing... plenty of fight on this stage and I finally ended up ordering a new housing with new bushing installed. I stil have the ole housing and the separate bushing waiting for next round

[dghii]

Originally Posted by Homeoboxter

Thanks for the tip, but the mount insert on this car was made of steel. So was the replacement. Steel insert in an aluminum housing. I can`t see how it`s possible to cut the insert out easily without damaging the aluminum bore. Scroll back, only the core part of the mount is aluminum, then rubber, then steel. And the steel shell is pressed into the aluminum housing. Maybe there are different versions?

I’ve done this twice....one on my car and once for a friend. It wasn’t tough to do at all and I didn’t score the inside bore of the mount. Just used a hand tool hack saw. When the cut was almost through, I used a screwdriver and hammer to chisel out the weakens, cut area.

I would have given up if it was hard to do!