3 Chain Engine Help

[granvillebarker]

I bought a 03 boxter last week with known problems ( water getting into exhaust ). I have the Bentley book and 101 projects book as well as a subscription to ALLDATADIY, but none of these resources seem to cover working on a 3 chain engine.

So far I have dropped the engine and transmission out of the car, and removed both heads. The are at a head shop getting pressure tested. Before I start putting all this back together I really want to make sure I have all the right information. So where should I look for specifics on working on a 3 chain engine?

It appears that I have all the common problems, chunks of water pump impeller were found in CYL 6 water port, and in the water cavity behind cyl 6 of the block. The rear main seal and IMS look like they could use renewing. I found a chunk of plastic over one of the chain rails that was either part of a chain rail or part of a air/oil separator.

I'm thinking of putting one of the GEBA water pumps with the metal impeller back in, in case more plastic chunks are still somewhere in the system.

Any resources for the 3-chain engine or feedback on using the metal impeller water pump would be appreciated.

Thanks,

Granville Barker
2003 Boxter 2.7L

[JFP in PA]

Couple of points:

There is very little information available for these engines outside of the OEM service manual sets, which are now out of print. You are going to need to search out one of these sets to get the best information.

Do not use a metal impeller water pump on any M96/97 engine. The clearance between the impeller and the engine case is very tight, so any wobble (and all water pumps wobble) is going end up with the metal impeller doing some impromptu machining on the cases, filling the entire cooling system with fine metal dust. They used composite for a reason.

[granvillebarker]

I kept digging and found a thread about the PIWIS at Porsche website, and for $1.80 per section, you can access the right info on there.

I've been reading the section on re-installing the head, and I have questions about the bold in the end of the intake camshaft. I have the tool to hold the outer collar in place, but I would like to understand what that is all about. What are we doing by holding that in place while removing the bold and reinstalling the bolt. Then it says remove the tool and tighten the bolt further.

Can someone explain what this is for?

Also that doc says to replace the bolt with a new one when reinstalling the head, but it isn't even listed in the standard head here on the Pelican website. Is this a hard requirement?

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Thanks,

Granville Barker
2003 Boxter 2.7L