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Pelican Technical Article:

Porsche Boxster / 996 Engine Teardown & Disassembly
Page 6

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Difficulty Level: 4
Difficulty scale: Adding air to your tires is level one
Rebuilding a Porsche Motor is level ten

  This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster.  The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads.   With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details. 
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Figure 1
We started today with some more photos of the missing rod.
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Figure 2
"Hello in there"
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Figure 3
Another shot of the short block.
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Figure 4
Another shot of the short block.
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Figure 5
Yet another shot of the short block.
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Figure 6
Hey look, another shot of the short block.
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Figure 7
Yes, it's yet another shot of the short block.
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Figure 8
Finally, the last shot of the short block.
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Figure 9
We had to remove the engine stand mount in order to gain access to the intermediate shaft bearing.
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Figure 10
Here's the magic bearing puller tool we used.  It fits inside the bearing, expands, and then you can use a big puller to snap the thing out of it's bore.  The bearing that was used in this engine is a dual-row bearing (more on that later). This bearing is held in with a snap ring that sits on the outside of the bearing.  With a large enough bearing puller, you can pull the bearing from the inside race and pop it out for replacement. This technique was pioneered by Scott Slauson owner of Softronic.
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Figure 11
Here's how the bearing puller fits inside the engine.
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Figure 12
Nice and snug.
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Figure 13
Tighten down the nut on the end to expand the jaws and lock it in place.  The bearing puller collet is made out of steel, even though these photos make it look like it's made out of aluminum.
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Figure 14
Here's our very large bearing puller tool.  
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Figure 15
Bearing puller tool from the opposite angle.
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Figure 16
Mount the puller tool against the case like this.
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Figure 17
Don't worry - doing this shouldn't damage your case as you're pulling the bearing out.
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Figure 18
Start cranking on it - it will require some significant force.  WEAR SAFETY GLASSES!
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Figure 19
Here it comes!
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Figure 20
Keep cranking...
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Figure 21
POP!  It will come out with a bang as the circlip pops out of its groove.
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Figure 22
Keep pulling and it will now easily come out.
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Figure 23
Here it is coming out about 1/4 of an inch now.
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Comments and Suggestions:
SOTIRIS Comments: Congratulation for all of these of information about a make with such history. My name is Sotiris from Athens Greece. A year ago I bought a Carrera 2001 third hand. The car is in a good condition but at 80.000 km change engine, a rebuilted one according to PORSCHE CORE in 2008 . From the factory the engine was M96 / 4_66120034 Now M9604AT66166310. Because of the many articles about IMS problems I would like to know how will be able to inform me about the Bearing in IMS which cause the fatal problem in the engine..
My car has also production No WPOZZZ99Z1S606579.
Thank you in advance
January 15, 2012
  Followup from the Pelican Staff: Model year 2006 - 2008, the intermediate shaft was redesigned, preventing replacement of the bearing without complete disassembly of the engine. If your engine was just rebuilt, the bearing should have been replaced. Keep up on your oil changes and regular maintenance to help increase the life of the bearing.- Nick at Pelican Parts  

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