Boxster Project 16 : Camshaft Upgrade / Chain Tensioner Replacement

Wayne 962 · Wayne 962's Garage

Anyone got any questions on Project 16 - Camshaft Upgrade / Chain Tensioner Replacement for your 986 Boxster, 987 Boxster, Cayman, Carrera 996, or Carrera 997?

Here's a back link to the original article: Pelican Technical Article: 16-ENGINE-Camshaft_Swap_and_Chain_Tensioner

-Wayne

Uberslider · 11-16-2010, 07:18 PM

Hello wayne,

I have a 1999 996 C2 6spd. and I believe i have a timing chain tensioner that is sticking. My car set for six months due to a broken left foot. To make a long story short I have what sounds like a chain rattle on the right bank (passenger side) In the past I would hear this for a second at start up. I am planing on replacing all three external tensioners and have read your right up (Camshaft Upgrade / Chain Tensioner Replacement) and I have a few questions. I am going to order the parts and tools needed from the Pelican wed site. I will order the P253 tools to set the cams in place and I am fairly certain I need two of them, one for each bank of cylinders. If I under stand this correctly from the first part of your right up, TDC for cylinder 1 is 360 off from cylinder 4,is this correct? Can I hold the cams in place on both sides at one time? If not when I replace the tensioner for the IMS which side do I hold in place? Is there any prep for the new tensioners before installation and is there a start up procedure? I also noticed in the photos in your right up that the spark plugs are still in the engine, can I spin the crank with the plugs in place? I would like to follow up on how helpful Pelican Parts has been in the past, the people on the phone have been a great deal of help with the 944 my son and I built for his daily driver collage.

Wayne 962 · Wayne 962's Garage

I would suspect from the description that it may indeed be an Intermediate Shaft Bearing problem. What you have described here is exactly what our 1999 996 sounded like at start up with that issue. With respect to your camshaft holding question - yes, the two banks are held in place at TDC for cylinder one - both at the same time with the tool.

-Wayne

ninja02 · ninja02's Garage

Hi Wayne,

I have a 2004 boxster and suspect I have a problem with the variocam(loss of compression on cyl's 1,2,3). You've mentioned in the book that there are photos for a later 3 chain model, but cannot access them with the link provided.

Phill

Wayne 962 · Wayne 962's Garage

Quote:

Originally Posted by ninja02

Hi Wayne,

I have a 2004 boxster and suspect I have a problem with the variocam(loss of compression on cyl's 1,2,3). You've mentioned in the book that there are photos for a later 3 chain model, but cannot access them with the link provided.

Phill

Well, when I finished up the book about a year ago, I had hoped I would have them done by the time it came to press. I have the engine, but they are not done quite yet.

That said, what have you done to measure the compression?

-Wayne

ninja02 · ninja02's Garage

Problem started driving home from work, Took my foot of the gas for the last corner before home and car stalled. Free wheeled home and car never started again for me. Tried numerous times and noticed fuel drippping from the exhaust for Cyl's 1,2,3. took car to local mechanic who checked the car and reported on loss of compression on cyl's 1,2,3. At present car is in my garage waiting time and funds to repair. Few people have mentioned it could be variocam problem.

Phill

UNYboater · UNYboater's Garage

Looking at pic 23, it seems that the tensioners are not likely to wear or go bad, but the guides/wear-pads look like they would. How much of this project is not needed if I have some worn pads/guides?

Meirschwartz · 03-19-2012, 08:45 PM

Quote:

Originally Posted by UNYboater

Looking at pic 23, it seems that the tensioners are not likely to wear or go bad, but the guides/wear-pads look like they would. How much of this project is not needed if I have some worn pads/guides?

And how they can be replaced.
They are not mentioned at all in the write up.
Thanks in advance.

Wayne 962 · Wayne 962's Garage

Although I haven't done it personally myself on an engine in the car, I believe that you can simply remove the chain ramp bolt and then slide out and replace the chain ramp. I believe there is enough access to do this, but I'm not 100% sure. Here's a photo from the engine teardown article:

-Wayne

Meirschwartz · 08:53 AM

thanks Wayne.
so basically by following those steps:
1. locking the camshafts at TDC.
2. removing the camshafts cover.
3. removing the chain tensioner.
4. removing the chain ramp bolt.
5. replacing the chain ramp.

the question is, if a worn IMS chain ramp is the one responsible for cam deviation,

or the ramps between the two camshafts?

frannyB · frannyB's Garage

Hi Wayne,

I have an '06 Boxster S (build date 1/06) and am having an issue I believe is a chain tension problem. If I start the car a few times and don't bring it up to operating temp (in and out of the garage) the next time I start the car I get quite a bit of ticking from the right bank. As the car warms up, the noise goes away and I don't hear it again. It has happened twice on me in the last couple years.

Could this be a tensioner issue? I have your book and it has been very helpful! You make reference to photos of the later engines but I can't find them on your site. I noticed above that you haven't quite made it to that bit yet, so I was wondering if you could give me your guess as to if I need to have my car looked (or do it myself) and what would be involved. Is my engine at risk?

Thanks so much and great work on your book and the rest of your site!

Franny

Bartok · Bartok's Garage

HI Wayne:
I purchased a 2001 Boxster S (35,000 miles on it) this August and have had the IMS, RMS, Water Pump and Thermostat replaced along with new plugs, tubes, and an oil change. Oh yea, engine and cabin air filters as well. I am looking at more preventative maintenance before the Spring. What other suggestions do you have? I have been considering the Variocam actuators but am not certain if the entire units need to be replaced or if separate pads are available for these.
Any suggestions would be greatly appreciated.
Cheers,
J

Pbadore · 11-21-2012, 07:14 PM

On my 2.7l 2001 5 chain Boxster engine the bank 1 cylinders 1 to 3 cam sprocket is turned to the right end of the four adjustment slots with the P253 adjusting tool correctly located. Is this normal or does indicate wear on the the chains, guides or sprocket teeth? The bank 2 cylinders 4 to 6 sprocket adjustment position is in the middle of the four adjustment slots. Both banks have new Porsche service part chain pads for the exhaust to intake Variocam tensioner/adjusters.
Also, the 101 Boxster project book was an huge help.

Pbadore · 11-22-2012, 08:02 AM

Quote:

Originally Posted by Bartok

HI Wayne:
I purchased a 2001 Boxster S (35,000 miles on it) this August and have had the IMS, RMS, Water Pump and Thermostat replaced along with new plugs, tubes, and an oil change. Oh yea, engine and cabin air filters as well. I am looking at more preventative maintenance before the Spring. What other suggestions do you have? I have been considering the Variocam actuators but am not certain if the entire units need to be replaced or if separate pads are available for these.
Any suggestions would be greatly appreciated.
Cheers,
J

Yes you should replace the Variocam nylon pads which are available separately at about $20.00 per set. Also, I would replace the O-ring seals on the return oil pumps, the Variocam solenoid seals and the green camshaft end plugs. I did mine with the engine removed from the car which made it easy to access the engine and retime the camshafts. The Sir Tools P260 timing set is nice to have when doing this job and is not too expensive (online at about $450.00).

Bartok · Bartok's Garage

Thanks for this Pbadore, I appreciate the feedback.
Jerry