pacificjuha

Coolant smell could well be that the coolant reservoir is leaking in to the trunk - water would not show at the trunk carpet, but under the trunk subfloor panel against the metal floor. The coolant reservoir is approx 500€ and the work is fairly fiddly to do, so I'd assume costly if not done by your self.

JES, the engine is alive!!! NO any chain rattle at the start up, no smoke at the start up and the idle is super smooth. The best part is that the throttle response is very very fast now 😎

P.S. How can I upload a video here? (Imgur is fine with images, but videos...)

Today was a day to install the engine and tranny back to the car with my teenage son. Just about all wires and hoses are now connected as are headers and transmission cables.

Tomorrow we'll install rest of the exhaust and other bit and peaces left to do - like throttel body to aircleaner connection and rear bumper. Then we'll turn then engine over for a bit without the fuel pump relay to get the oil circulating... then hopefuylly start the car... I have to admit that I'm a bit nervous... hopefully all goes well 😅

If you have not yet planned as a part of your trip and dates will allow, make it a point to visit at the LeMans at the week of the 100 year celebration race at LeMans (5-11.6.2023). I'll go there from Finland with my 2001 Boxster as a son & father trip.

Finished the engine, clutch and tranny package.

Today installed new sparkplug tubes with new seals, sparkplugs, coils, cam plugs, fresh Porsche tranny oil, new chain tensioners and connected the tranny to the engine with all new clutch parts.

Next step is to lift this all in to the car.

Spend this weekend some great time at the garage with my son to just about finish off the engine built.

Only thigs left is to change the old chain tensioners to new ones - I forget to buy oil to prime the new tensioners...

Another to do before installign this engine / tranny -package in to car is to chage the transmission oil.

Today picked up the flywheel and clutch kit from balancing.

Flywheel was 1,5 grams off and pressureplate was 3 grams off. Now all this is zeroed

This weekend is a plan to change the IMS bearing and RMS. If there is time left, plan is also to install the new vacuum reservoir, intake manifold, fuel injectors and throttle body. Gettin close to re-install the engine & tranny to car 😎

Changed the chain ramps also on the bank 2, then timed both bank 1 & 2 cams and installed the cam covers back.

It was rather nerveracking to tinker with the cam timing - basicly one chance to get them right to avoid carnage at the firsta start after rebuilt 😬

Oil pump also looks very good. The oilpump use axle shows small wear (new axle will be installed next weekend).

On the bank 2 VarioCam follower was a bit more worn out than bank 1. On both banks, the heavy wear showed on the chain pad where is the oil channels (two small holes).

Large chain ramps show basicly no wear on either banks.

Today was a surprise find at the garage regarding the throttlebody.

I did clean it 30.000km / 2.5 years ago and it looks again like this:

Good scrubbing with carbcleaners help it's much better:

I have been using only OEM air filters and changing those annually, but this throttle body still get dirty... any idea why?

Today accomplisment was also cleanign of the intake runners and I did change all vacuum hoses on the engine and tested the check valve and one way valve which were both in a great condition. Next weekend the fun continues.

Check with Dougals valley. They have at least some of the parts you're looking for and will ship.

Parts are used, but good condition original part will last for many years more. Here's couple of backboxes they have right now: https://www.douglasvalley.co.uk/prestige-parts/?b-porsche:ct-exhaust-boxes:xt-porsche-boxster-986

Today we did spend a bit of time at the garage again.

Took the starter apart, cleaned it and rebuilt it with fresh lubricants. Starter did make some noice few times very seldom during cold and moist weather last fall. Now the pinion gear returns very nicely compared to the pre-servicing situatuation in the morning.

Took images of all intake- and exhaust valves from the port sides and those look real good. Also this engine has not used basicly any oil during 5-7K km oil change intervals - assuming that valve seals are not leaking.

Then opened up the oil pan was expecting some surprises there... For a fantastic news there was pretty much nothing to be found, only few small peaces of brown plastic most likely from chain guides.We also tried to pick up the brown small peaces with magnet, but no chance since the brown plastic does not really stick on magnet

The oil pick up was also clean.

I'd call this a good father & son day at the garage

On this weekend we'll probaly replace all chain guides on one of the cylinder banks - also the VarioCam pads.

7 hours ago, jonogt6 said:

Good job you had plenty of rubber gloves!  😃

Bought a box of those gloves and bag of zip-ties just for this purpose 😁

Today spent part of the day with my son at the garage doing last wrenching for the 2022 on the Boxster.

Rebuilt driveshafts, cleaned the engine and rebuilt the engine mount with PowerFlext yellow inserts.

Separated the tranny from engine and took off the clutch & flywheel.

The IMS cover had made a mess there. The double row IMSB and clutch was changed approximately 100.000km ago by indy shop. Looks like RMS has been holding oil in the engine well:

To my surprice it looks like during last clutch change the double mass flywheel was sanded at least a bit. This time I'll be installing a new flywheel, clutch pressureplate etc goodies.

Durign Christmas holidays I'm plannig to clean the tranny and engine before the maintenance work.

1 hour ago, ½cwt said:

Nice work and great as a family exercise.  Oh for a workshop and 2 post ramp!!!

Thinking of a recent 987 post, can you loot at the end of you fuel rails and see if there is any corrosion please?

@zcacogp

This engine has plenty of dirt, but have not seen yet any rust on the car (only on exhaust clamps and muffler).

Next to-do item is to figure out how to clean this as easy as possible without damaging the aluminium with too strong detergent... anybody here have good recommendations?

Had yesterday some quality time with my son... pulled out the engine and tranny

Next is cleaning, chain ramps repalcement, RMS, IMSB, flywheel, clutch, vacuum hoses, etc fun with my son.

Good and complete service history from 2001 - including original windowsticker etc - was a good info for me when i purchased my current Boxster 4 yeas ago.

Now I'm DIY pretty much all, but keep every receipt with km's and dates the work is done. The MOT is stating in suprised manner each year that 'this car is in MOT perspectice like new'.

With this kind of history available and taking in to account this is totally rust free, I have received few offers to sell (not selling ) regardless of rather high traveled car of 299.567km (approx. 186.000mi) to date.

Anyhow, service history is not important at all to most buyers as these cars are getting very old - still these are sooooo much fun.

How about the seal around the mirror 'triangle'. This seal being not seated well or being worn out causes sometimes leaks to the doorcard.

Could it be that abs pump activates the right front corner? If yes, could be the abs sensor on that corner going bad and giving a faulty signal to the abs brain. This is a wild guess...

On 5/8/2022 at 11:47 PM, David__H said:

So, interesting few days playing around with suspension!

First off, in looking at various Youtube videos on coilovers for road use I came across a video from the US about appropriate spring rates for road cars (I guess useful for people who aren't buying an off the shelf product designed for their particular car). The advise was you want a spring that compresses somewhere between 25% and 35% of its length with the weight of the car applied. This means the spring is soft enough to provide sufficient compliancy for road use, but will have a good degree of suspension travel left when under load.

So, this info was interesting because I was wondering if the springs on my Gecko Street kit were too soft. So I thought I'd try measuring them. Having measured the spring lengths with the car sat on the garage floor and then with it jacked up, I calculated a spring compression of 23% on the rear and 22% on the front. The measurements weren't exact since they included part of the perch rings and top mounts, since I could see them with the car sitting on it's wheels (the bottom of the springs is invisible). Two points learned from the exercise: No my spring rates are not too soft...they're actually at the hard end of the recommended range and secondly, very impressed that the springs have been clearly well matched to the expected load since the front and rear compress the same percentage.

 

Very good and interesting info,thank you.

Do you know what is the spring values on your setup front and rear lb/in OR kg/mm?

I have 2011 Boxster that I do track a lot, but drive on street as well and am looking for a spring strenght to select for a new set of coilovers to be installed over the winther.

Yesterday took the car for the season finale drive on a spot on fantastic weather.

19 minutes ago, Daboy3000 said:

Great, Thanks for that.

How much did you source one for?

Purchased used one from EU Porsche broker (teile.com at Germany) to stay away from import taxes and customs duties.

Check out from Steve & Douglas Valley breakers - he should have this for you at reasonable price and in UK:

https://www.douglasvalley.co.uk/prestige-parts/?b-porsche:xt-porsche-boxster-986

New part is very expensive...

27 minutes ago, Daboy3000 said:

I found out that my heating only blows hot on "HI".     

Any insight would be great.

I had exactly the same issue and the cure was to install a new cabin temperature sensor. Here's what I did:

Yesterday took a nice evenign drive to local Porche event. It was most likely the last fairly warm great sunset drive weather for this season. At the end of the month is time to take the engine & tranny out for a maintenance overhaul, so let the rain and snow come