OT: 2003 Boxster S engine replacement Options

[Jake Raby]

Whoops, found some more pics from a few years ago at our old store. This would be a IMS replacement. I usually only take pictures for warranty claims to document the work performed. Of course according to our wonderful arrogant friend, the dealerships aren't smart enough or competent enough to do these and only one person on earth can. Oh well. My bad.

Just in case you want to assemble the engine my way... Here is a sample page from the M96/M97 Definitive Guide that goes over bearing fitment and crank carrier assembly.

[HAM Inc]

I've seen a good deal of Jake's book as it's progressed. It's going to be extremely informative and answer a lot questions that enthusiast have about these engines and serve as a great hands-on guide for pros.

I'll bet that even some folks who don't like Jake will benefit from it!

Nice work Jake! Takes a lot of dedication to pull off something like this. (IMG:style_emoticons/default/beerchug.gif)

[Kraftwerk]

Something here reminds me of the East Coast / West Coast rap rivalries of the mid 90's ala Tupac vs Biggie..

That said its good to know that Boxster's blow up as easily as Cayman's and Pannamera's, now has anyone ever put PCCB brakes on a 914?

[jesiv]

So tomorrow they are finally pulling the engine from my car. I should know cob tomorrow buildable or not! I am prepared either way. I either have my Boxster back or a new project! Could be fun either way!!

More HP (IMG:style_emoticons/default/piratenanner.gif)

Wish me luck!!!


Regards

James

[Jake Raby]

So tomorrow they are finally pulling the engine from my car. I should know cob tomorrow buildable or not! I am prepared either way. I either have my Boxster back or a new project! Could be fun either way!!

More HP (IMG:style_emoticons/default/piratenanner.gif)

Wish me luck!!!


Regards

James

No matter the outcome we'll help you get out of trouble. :-)

[jesiv]

Well I went over to the Porsche dealership to see my car. The engine had been removed and the head had been disassembled. The initial inspection has not revealed any indication as to the source of the coolant leak. There is no intermix. Just coolant in the mid cylinder on the driver's side bank 2? The is no indication of any cracks in the head or cylinder wall and the head gasket's integrity was solid. The are no visual indicators to reveal a failure. I am no expect but I can vouch for the visual inspection.

Appears the next step is to have the head inspected locally. I my be getting ahead of myself but what if the head is sound.

So I guess the questions are

If the head is repairable -- send to ham?

If head needs replacing -- source head?

If head is sound -- split case??

Just get another car and make it a project :-)


Regards

James

[euro911]

Just a thought, since the head and gasket appear to not be the issue - Is it possible there is a breach in the cylinder wall?

Have them rotate the crank to lower the piston in the bore (IMG:style_emoticons/default/confused24.gif)

[Jake Raby]

You have to find the smoking gun. Lots of times to find cracks you need to use a heat gun to get things to expand.

Len can find a crack in the head thats not visible through his pressure test. There's one crack in these heads that requires an odd means of pressure testing and your symptoms sound like that might be the crack that you have.

Don't become defeated, its just a matter of finding the issue. Did they pull both heads? The issue might be on the other side and has cross pollinated to this side. I'd pull BOTH heads, no matter what.

[jmmotorsports]

Don't flame me for the Boxster post please! I have a 1975 914 just looking for advice. I am thinking there are more experienced Boxster owners here than most sites.

I am having my 2003 Boxster S towed to the dealership tomorrow. I replaced the IMS with the LN bearing last year as an FYI. On the way home from work last night my idle was rough. The highway was normal and spirited! With no problems. However when I started the car after leaving the grocery store. Smoke was apparent thru the rear window. I couldn't tell if it was white or any other color as it was dark. The car ran fine but had a rough idle in the driveway prior to shutoff. I didn't feel good about how things were going! The next morning when I started the car no smoke but rough idle! I didnt see any reason to push the situation so I stopped the engine. I have no check engine light!!

I don't think the engine is blown but it has me thinking... I could hear from the dealer I need a new engine!

So what I would like is your suggestions on is... other than a 25k porsche crate motor... What would you do? The car is perfect otherwise!

I should add this is a daily driver. No track. Like I said it is perfect otherwise

Thanks for the help!!ls1orls3

Regards

James

[rfuerst911sc]

jesiv not sure if this will help you or not but yesterday I met Jake for the second time. First time was a social meeting but yesterday was for car business. He walked me through his facility and told me about things he has going on. He shared some stuff about these cars and I was blown away by his knowledge and passion for these cars. We have a handshake deal on a project and I have zero concerns about the deal. I found him to be a man of integrity. If anyone can walk you through this it will be Jake and his crew. If you need a shop to fix your car/engine Jake's is the way to go in my opinion. Good luck with the engine.

[HAM Inc]

Jake is a man of integrity. 11 years of doing business together has proved that to me.

As for the visual inspection of the heads; that won't cut it. Some cracks jump right out you, some don't. And one in particular you never see, even when pressure testing. You just see the bubbles.

Please don't ask me to share more details. I'll help to a certain point, but I won't hand on a silver platter to our competition what we've learned through hard work and diligence.

I can repair any crack, though one requires more work than a replacement cost.

[jesiv]

Jake is a man of integrity. 11 years of doing business together has proved that to me.

As for the visual inspection of the heads; that won't cut it. Some cracks jump right out you, some don't. And one in particular you never see, even when pressure testing. You just see the bubbles.

Please don't ask me to share more details. I'll help to a certain point, but I won't hand on a silver platter to our competition what we've learned through hard work and diligence.

I can repair any crack, though one requires more work than a replacement cost.

Len

I am just trying to figure out what has failed, the head or the block/cylinder. If I can determine the failure. I can scope the repair. If the head then I will immediately proceed with repair. If not, then it becomes a project. If it is the heads then my plan is to send them to you. I am not trying to get something for nothing. I am just trying to figure out where I stand. Thank you for your help!

Do you have repaired heads for my 2003 Boxster S?

Regards

James

[HAM Inc]

James take a look at this short video. http://www.youtube.com/watch?v=qsnbhLwkjCs
This crack was not visible to the naked eye.
The head in the vid is a 3.4 and different from your's, but does give evidence of the minuteness and difficulty of spotting some of these crack.

Based on the info you've provided I have an idea that yours is in this category and is likely of the variety that will have to be pressure tested to locate. Jake and I talked about your symptoms and we think it might be a rare type of crack that we have found with your model only (so far) and occurs deep in the head, out of sight.
Both heads should be checked.
Hope that helps.

[jesiv]

Len

I assume the deep cracks would not be repairable and thus only option is to get new/rebuilt heads?

Regards

James

[euro911]

... and would the replacement heads exhibit the same issue? (IMG:style_emoticons/default/sad.gif)

[HAM Inc]

Len

I assume the deep cracks would not be repairable and thus only option is to get new/rebuilt heads?

Regards

James

James the short answer is yes. We can repair that crack, but it takes so much time that a replacement makes more sense, at least at this point in history. Some day that particular head may be valuable enough to justify the time.

[HAM Inc]

... and would the replacement heads exhibit the same issue? (IMG:style_emoticons/default/sad.gif)

A replacement would have to be pressure tested for sure.

The deep crack in question is the rarest of all the cracks we see, so the odds are in Jame's favor that a replacement is usable.

Core shift is the apparent cause of this issue and that can not be seen from the outside of the head. Have to cut it open to get a look at it. I've cut open and repaired a lot of M96 heads and damn near every cracked head had a core shift during the casting process.

I started repairing cracked aluminum heads in 1987 and over the years most suffered with some degree of core shift.

[rhodyguy]

Sloppy casting process. I wonder who did/does their foundry work. I would think they used a permanent mold.

[HAM Inc]

Sloppy casting process. I wonder who did/does their foundry work. I would think they used a permanent mold.

I'm no expert on the casting process, but past research revealed that molds have a life span. Core shift in production casting is largely accepted and good design engineering takes a certain amount of it into consideration.
Every head I've worked with over the years that I saw a lot of cracks with were in want of just a few ounces of strategically located aluminum to prevent issues. Bean counters are the likely culprit.

The 9A1 heads are the most complex castings I have ever seen. I would love to see how they're cast.

[rhodyguy]

is that after your work pictured?