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Pelican Technical Article:

Porsche Boxster / 996 Engine Teardown & Disassembly
Page 8

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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
Here's the engine / short block it sits after removal of the heads, and the intermediate shaft bearing near the crankshaft.
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Figure 2
Another view of the short block.
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Figure 3
Here I show the intermediate shaft bearing that came from the engine (left), and the LN Engineering bearing upgrade kit (right).  The original bearing is a double-row bearing, and is shown with the original thin-flange cover.  The LN Engineering upgrade kit contains a special ceramic bearing, and an updated billet-machined cover plate.
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Figure 4
Here's another photo of the side of the engine.
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Figure 5
Another shot of the missing rod / piston combo.
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Figure 6
Upper chain rail, which we will be removing shortly.
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Figure 7
Photo of the short block with the intermediate shaft bearing removed.
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Figure 9
Here's a close-up view of the bearing puller tool that we used to remove the intermediate shaft bearing (Stahlwille 11060-2 Internal Puller18-23mm and Stahlwille SF11061-2 Counter Stay).
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Figure 10
Here's another shot of the damaged piston.  Note the damaged cylinder liners (cracked in three places).
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Figure 11
Close-up of an undamaged cylinder.
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Figure 12
Close-up of the cracked cylinder liners.  These are cast into the case as one piece (saves manufacturing costs).
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Figure 13
Damaged piston, cylinder #1.
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Figure 14
Damaged rod on the opposite side, cylinder #4.
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Figure 15
Crankshaft pulley and the large water-channel area off to the right.
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Figure 16
View from the top looking down.
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Figure 17
Here's our disassembled parts all laid out in order of how they were removed from the engine.  The long rod in the center of the photo is the oil level sender / oil temperature sender.  These two senders are integrated into one.
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Figure 18
Alternator, front oil pump housing, thermostat
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Figure 19
Head bolts, oil pump, and associated hardware.
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Figure 20
Cylinder head (4-6), view from where the camshafts are attached.
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Figure 21
Damaged cylinder head (1-3), view from combustion chamber side, with missing valve.
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Figure 22
Valve cover with camshafts, and cam follower housing.
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Figure 23
Valve cover with camshafts, cam follower housing, and the cam followers in place.  This is a great way to store the entire assembly, particularly if you are planning on putting the engine back together.
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Figure 24
Power steering reservoir, starter, oil cooler, camshaft oil pump, spark plug coils, front bracket for idler pulley, spark plugs and spark plug tubes.
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Figure 25
More miscellaneous stuff on the bench...
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Figure 26
Water pump, oil pump, water housing.
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Figure 27
Cylinder head, camshaft housing, etc...
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Figure 28
We need a bigger table!
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Figure 29
Backside of cylinder head.
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Figure 30
Damaged head and opposite piston.
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Figure 31
Photo of damaged cylinder head.
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Figure 32
Here's our project car on the hoist at Callas Rennsport for their Boxster / 996 Tech Session.  The car already has the 996 3.4L engine installed!
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