2001 Boxster S Engine (M96/21) Rebuild
 

I always tear open the old oil filter after every oil change. In the past I have been fortunate in that I haven't found any foreign materials in the filter, but recently, at 187,000 miles on the odometer, my filter was covered in bits of plastic that look like chain ramp material.

http://i983.photobucket.com/albums/a...psfebfa1d5.jpg

A quick check of the camshaft deviation showed that the timing is out of spec. I wasn't able to find out if the limit specified by Porsche is +- 4 degrees or +- 6 degrees. Regardless, mine is well beyond that.

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My wife has been driving the car lately and she noticed some engine codes that seem to go away on their own every now and then. It turns out the codes indicated that the camshaft deviation was out of spec. So, even though I wasn't planning on it, I decided to pull the engine out and tear it down. I was suspecting that some of the chain ramps (particularly those on the Vario Cam units) are really worn down.

First step - engine out.

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Intake manifolds and other ancillaries removed.

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Long block. Gotta love the mess left behind by the power steering reservoir and its leaky habits.

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Engine stand plate attached.

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First order of business was to turn the engine upside down to soak the header bolts in WD40. I really didn't want to snap any.

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Luckily they all came out with no issues.

http://i983.photobucket.com/albums/a...psaxgbcpyf.jpg

Time for some brief cleaning before the tear down.

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And ready to start removing the 1 - 3 cylinder head.

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Camshaft hold down tool installed.

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Oil pump removed.

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Valve cover removed. Very happy with the wear on the camshafts.

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Camshafts removed.

http://i983.photobucket.com/albums/a...psth4iudrw.jpg

Lifters (valve tappets) removed.

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Lifter housing removed.

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Cylinder head removed.

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Cylinders look beautiful IMO.

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Repeat the process for 4 - 6 cylinder head.

http://i983.photobucket.com/albums/a...psklmepf9v.jpg

Short block.

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Oil pan removed. Nasty looking sump.

http://i983.photobucket.com/albums/a...psxpdhceiz.jpg

4 - 6 cylinder case half removed.

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Crankshaft carrier removed.

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IMS tensioner paddle not so happy.

http://i983.photobucket.com/albums/a...psie8mhq30.jpg

Likewise, the Vario Cam chain ramps were incredibly worn down. I'll post pics when I separate them from the chains and camshafts. So there you have it. Engine tear down complete. I'd say that process was pretty straight forward. My brother, Ion (fcotanis on Dorki), helped throughout. It took the two of us 14 hours to tear the engine down. This included some cleaning time and a couple of meals.

Here is Ion ready for battle.

http://i983.photobucket.com/albums/a...pssi28cfk7.jpg

I am currently forming a list of parts to order and will post more pics here when I begin the assembly.

Show off!!

Any chance the codes were camshaft sensors that I've been getting? It put me in limp mode a couple of times.

Attachment 44095

I believe I've met your brother, Ion. Is it pronounced "John" in English? I believe we met at VIR either last year or the year before.

4403 looks familiar. I believe that's what I had. In your case, I'm not sure if 4903 refers to a second sensor on bank 1 or just bank 2. We're talking 986 vs 987.2. When you get a chance, connect your Durametric and at idle go to the "actual values" menu and look at the camshaft deviation on both banks.

Yep - you're right. He can confirm.

Mihnea! You should have called me :) I'll be tearing down two this winter. I suggest that you get the billet paddle from LN while you are in there. Also, remember that if you are considering addressing the IMS bearing now is the time!

That sump is ugly. I actually haven't seen one that gummed up on an M96/97. Even with black oil coming out the sumps have always been spotless. Did it wipe clean? If it did maybe it was because you opened it upside down and that is just what would have drained out?

6 degrees, btw

Pretty sure it's pronounced Yon but he doesn't seem to mind EYE-on or Eee-on.

Saw that on your post and will take a look. thanks

Ha ha - I only said that taking it apart is easy. Putting it back together is a different story. We'll have to see how that goes. Also - just so everyone here knows - I have no idea what I'm doing when it comes to engine work, so yeah... it should be fun. I hope I won't screw up the timing or something and turn this thing into a pile of twisted metal. Actually, my plan was to let Ion do the timing so that I could blame him when this thing inevitably blows up.

I had him as a student at VIR. When I saw his name, I approached and said "Hi, my name is Rob", and let him pronounce his name. :)

Good driver, BTW.

Tear down is trivial - just carefully bag and tag everything.

Assembly and timing..... :) I'd be glad to help. Are you just replacing the paddle and reassembling or are you tearing down all the way and having work done? Reassembly from here is straightforward and you only have to worry about timing. Once the rods are out the assembly jumps up a level in difficulty on the circlips, especially if you haven't done one.