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> OT: 2003 Boxster S engine replacement
Jake Raby
post Dec 14 2013, 04:47 PM
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Don't put the cart before the horse.. Find the crack!!!
You MUST find the smoking gun, no matter how hard that may be.

If not, it will find you.
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HAM Inc
post Dec 14 2013, 04:52 PM
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QUOTE(rhodyguy @ Dec 14 2013, 03:47 PM) *

is that after your work pictured?

All of the machine work in that pic is Porsche. My work is on the other side. That's after a run through the ultrasonic tank. Shiny shiny. And one seriously complex casting with a damn near equally complex machining regimen.
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Jake Raby
post Dec 14 2013, 06:48 PM
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QUOTE(HAM Inc @ Dec 14 2013, 02:52 PM) *

QUOTE(rhodyguy @ Dec 14 2013, 03:47 PM) *

is that after your work pictured?

All of the machine work in that pic is Porsche. My work is on the other side. That's after a run through the ultrasonic tank. Shiny shiny. And one seriously complex casting with a damn near equally complex machining regimen.



That head is from a 2013 Porsche engine.

Check page 66 of your Panorama this month for 5 pages of details concerning what we've created for that platform.
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r_towle
post Dec 15 2013, 11:34 AM
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Curious,
Can you buy a new head from porsche to replace one that is cracked?
They must have spare parts still????
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Woody
post Dec 15 2013, 12:03 PM
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QUOTE(r_towle @ Dec 15 2013, 11:34 AM) *

Curious,
Can you buy a new head from porsche to replace one that is cracked?
They must have spare parts still????


Yes
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jesiv
post Dec 15 2013, 03:10 PM
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Yes. The dealer has stated ~3k for just the head. If mine can't be repaired. I would prefer to get a quality rebuilt head to keep cost down.

Regards

James
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DBCooper
post Dec 15 2013, 03:22 PM
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Well, I have to say that this thread has pretty much eliminated any interest I had in getting a Cayman.
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jesiv
post Dec 15 2013, 05:47 PM
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Yes. The dealer has stated ~3k for just the head. If mine can't be repaired. I would prefer to get a quality rebuilt head to keep cost down.

Regards

James
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jesiv
post Dec 15 2013, 05:47 PM
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Well given my Boxster is not getting fixed in the near future and it was my daily driver, I leased a 2014 VW Jetta SE for two years. The lease was zero down $230/month for two years and 30k miles. The car is not sporty but will get me back and forth to work. After driving the rental car and the Jetta, I sure miss my Boxster. My son is a senior in high school and the 914 is his daily driver. When I got the Jetta, the first words out of his mouth were... With a horrified look, he asked. Dad your not going to take the 914 are you!! LOL!!

Now I have time to fix the Boxster right. I have never turned a wrench on the Boxster. I never had to. While I have rebuilt one 914 engine, I have maintained all three of my 914s 71/6 76/2.0 and the current 75/1.8. Don't ask about the six. I am looking forward to working on the Boxster. While I thought access to the top of the engine on the 914 was limited. The Boxster access makes the 914 top engine access seem like on 1950 chevy. You know where you could sit in the engine compartment! I am concerned with the apparent need for specialized tools to work on some areas and the computer on the Boxster!!

Jake you mentioned not to get the cart before the horse. I absolutely agree! I plan to have the head inspected locally to get an idea of what is going on. I expect the next step hopefully will be to send both heads to Len to be rebuilt. Then hopefully put it all back together and I have my Boxster back :-)

The dealer did find a piece of the WP impeller when they removed the thermostat. They also found gouges from when the removed the WP. Obviously my WP failure was more catastrophic than I was previously told! That being said, I could not believe the total lack of oil on the exterior of the Boxster engine! I kind of expected the engine to be caked in oil and dirt like my 914. That was a real surprise!

Any ideas on the type of engine stand I will need. Is there one that works for a 914 and Boxster?

Regards

James
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euro911
post Dec 15 2013, 07:26 PM
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QUOTE(DBCooper @ Dec 15 2013, 02:22 PM) *
Well, I have to say that this thread has pretty much eliminated any interest I had in getting a Cayman.
(IMG:style_emoticons/default/agree.gif) I'm sticking with air-cooled (old school)


The reason I asked about checking the cylinder(s) for cracks ... Click here

Attached Image
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jesiv
post Dec 15 2013, 08:21 PM
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Not debating air cooled! I don't have any intermix of coolant and oil. Just coolant and exhaust. I can't wait to know what the root cause is!

Regards

James
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Jake Raby
post Dec 15 2013, 08:21 PM
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QUOTE
The dealer did find a piece of the WP impeller when they removed the thermostat.


And there ya go.

Len will probably find more of them inside the heads after ultrasonically cleaning them and the waves knocking them loose.

I more than likely have a good 3 chain head if you need it.
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HAM Inc
post Dec 15 2013, 08:30 PM
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I wish like hell I'd saved the bag of blades I'd been collecting when we moved. Would make quite a show & tell photo! I'll start another bag and likely have a good size collection again in no time.
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euro911
post Dec 15 2013, 08:39 PM
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Interesting. We had a WP disintegrate in a '98 VW Beetle. The car continued to overheat after a new pump was installed, so I bought an inspection camera and will look for an errant piece of the impeller in the water jacket of the block.

(IMG:style_emoticons/default/popcorn[1].gif)
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HAM Inc
post Dec 15 2013, 08:55 PM
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QUOTE(euro911 @ Dec 15 2013, 07:39 PM) *

Interesting. We had a WP disintegrate in a '98 VW Beetle. The car continued to overheat after a new pump was installed, so I bought an inspection camera and will look for an errant piece of the impeller in the water jacket of the block.

(IMG:style_emoticons/default/popcorn[1].gif)

It's a bitter pill to swallow, but these aren't our grandpa's engines with cast iron pumps and water jackets that are open and free (too free) flowing. When a plastic pump fails localized over heating becomes a real possibility. Frankly I'm a little surprised with how many mechanics don't have this on their radar.
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gothspeed
post Dec 15 2013, 08:59 PM
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QUOTE(HAM Inc @ Dec 15 2013, 06:55 PM) *

It's a bitter pill to swallow, but these aren't our grandpa's engines with cast iron pumps and water jackets that are open and free (to free) flowing. When a plastic pump fails localized over heating becomes a real possibility. Frankly I'm a little surprised with how many mechanics don't have this on their radar.

+1 ....... I have seen the plastic impellers 'spin' on the metal shaft ...... and people wonder why the engine is over heating .... (IMG:style_emoticons/default/sad.gif)
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HAM Inc
post Dec 15 2013, 09:03 PM
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QUOTE(gothspeed @ Dec 15 2013, 07:59 PM) *

QUOTE(HAM Inc @ Dec 15 2013, 06:55 PM) *

It's a bitter pill to swallow, but these aren't our grandpa's engines with cast iron pumps and water jackets that are open and free (to free) flowing. When a plastic pump fails localized over heating becomes a real possibility. Frankly I'm a little surprised with how many mechanics don't have this on their radar.

+1 ....... I have seen the plastic impellers 'spin' on the metal shaft ...... and people wonder why the engine is over heating .... (IMG:style_emoticons/default/sad.gif)

Yep. But, as long as the customer shut it down before letting it overheat, the spinning impeller is easily the preferred type of failure. At least the blades are all there, assuming it hadn't shed some before it started spinning.
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gothspeed
post Dec 15 2013, 09:13 PM
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QUOTE(HAM Inc @ Dec 15 2013, 07:03 PM) *

Yep. But, as long as the customer shut it down before letting it overheat, the spinning impeller is easily the preferred type of failure. At least the blades are all there, assuming it hadn't shed some before it started spinning.

Agreed ..... sadly I have even seen a 'new', freshly installed water pump do this 'spin' thing ..... what a pain ..... (IMG:style_emoticons/default/headbang.gif)
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Jake Raby
post Dec 15 2013, 09:17 PM
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QUOTE
Frankly I'm a little surprised with how many mechanics don't have this on their radar.


When I instruct my M96 class an average class has 35 attendees. When I get to this topic maybe 1-2 of the attendees will have a clue about this.

The rest are generally poseurs who come to the class to gather more certificates to hang over their tool box.

This post has been edited by Jake Raby: Dec 15 2013, 09:18 PM
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jesiv
post Dec 15 2013, 10:05 PM
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I am surprised as well! I faithfully executed every recommended service item recommended prior to interval. However, I was never told about the water pump maintenance issue. Would have gladly replaced a WP w
vs an engine!

Regards

James
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