Of course, if it does, you need to replace the complete hose and not just the connector. Puristic, fast, emotionally evocative—the new Porsche Cayman GT4 blends mid-engine fever with racing genes. There’s no doubt that a cheap sealed bearing of the kind that sits at the end of the intermediate shaft on an M97, has no place in a performance engine. This happens on all models and usually shows up as a coolant smell while driving with minor loss of coolant over a period of time. One of the most common, misunderstood and potentially destructive issues on the Cayman, is an oil leak from the rear main seal. 2004 996, 2005 Carrera, 2005 997, 2006 Carrera, 2006 997, 2007 Carrera, Use a high-lift jack on the rear axle support bar to raise the chassis higher. This is almost impossible to see or clean out without the bumper being removed. The AC compressor for example, rarely has issues and a low refrigerant situation can prevent the compressor from engaging. To access the battery or engine compartment requires battery power for the electric hood release – not easy with a flat battery. The plastic impeller can degrade rapidly and spread flow-blocking plastic throughout the cooling system. Porsche führte danach den Boxster und Cayman unter der Baureihe 718 zusammen. Creative can often translate to money saving. If you’re researching and considering buying a Cayman, our used car buyer guides highlight mechanical issues to be aware of before you complete a purchase. However, replacing the AOS sooner rather than later can be a good precaution against other failures. The car referenced in this project is my 2000 Boxster which I purchased with a broken engine. There are however, a number of weaker areas that can sometimes cause issues. The upgraded AOS features a doubling in size of capacity for scavenging and is less prone to sucking up oil during high speed cornering. However, the hype generated by people who have to gain from identifying the problem with this bearing and the real world results don’t quite match. Remove transmission (Under trays, Support braces, O2 sensors and exhaust, Muffler, Empty coolant and remove all coolant hoses (, Disconnect power steering lines (Photo 8 and, Remove power steering line from support bracket (, Loosen power steering return line at junction in engine compartment (. If you have a zip tie handy, you might want to zip it to the support brace so that it doesn't get in the way when lowering the engine. The faults are an indication of the symptoms and not the route cause. I recommend that you inspect and replace the clutch disc when you have the engine out of the car. The key includes a small electronic transmitting device that is matched to the car and a small battery to power it. The new mid-engine sports cars are powered by a naturally-aspirated four-liter six-cylinder boxer engine developing 394 hp and 309 lb.-ft. of torque. The cam solenoid is an electro-mechnical device that redirects oil pressure as per the demands of engine management. 1” Roadster – the car that defined the beginnings of the Porsche brand – featured the mid-engine, and in the 1950s the same layout was chosen for the 550 and 718 racing cars. If you have to remove a hose with this type of connector ensure that when replaced it does not leak under extreme pressure. Regardless of how you raise the car, always practice extreme safety: take your tires and wheels and stack them horizontally under the car just in case an emergency arises (the car will drop onto the tires and wheels). Remove Vin Without Images . Take care when lowering that they don't get crush, scraped or damaged. Remove the clamp and then pull off the hose. Disconnect it from the engine by removing the bolt shown (yellow arrow). Click to see bonus pictures for this project. Shown here are the fuel line connections. A small plastic circlip near the white connector attaches it to the other line. See The Official Book Website for more details. More than 90 Days [3] 30-60 Days [1] 15-30 Days [3] Key Features . On the 1999 and earlier cars, the throttle was controlled by an actual cable. Loosen the clamp (purple arrow) and you should be able to pull the filler neck out. The procedure for securing the camshafts and accessing the primary timing chain can be difficult with the engine installed. One of the most frustrating leaks is a small crack in the coolant reservoir. It’s a superb small two seat coupe that handles nicely, is well balanced and looks like a Porsche! The lifter commonly breaks and during the second stage of valve lift, which occurs above 4k rpm, it does not function correctly – this results in a misfire on a single cylinder. This photo of the engine with the transmission removed shows location and type of the fasteners that attach the transmission. It’s supplemented by wires that are coated with a plastic made from corn and on cold, long dark winter nights when food is in short supply, that wire seems pretty tasty. Time: 1 hour 1 hr: Tab: $35 to $100: Talent: * Tools: T30 Torx, trim removal tool, Philips head screwdriver: Applicable Models: Porsche 987 Cayman (2007-08) Porsche 987 Cayman S (2006-08) Parts Required: Filter: Hot Tip: Clean the … The manual transmission rear section is very solid and reliable. These devices are managed by a control module attached to the Mechatronic unit. Make sure that your assistant is watching the surface where the engine and the rear axle support bar meet to keep tabs on the progress. In many cases, this could also point to a faulty MAF, but it is common for the Cayman to experience a vacuum leak through a cracked intake or vacuum hose that looks like a MAF failure. This can be extremely destructive, although if you have this problem it’s kind of too late. However, if you have replaced both the coil and the plug and still have the same problem, there is another solution. Valve cover leaks are obvious and fairly straightforward to fix on most models. The changing mixture can cause over fueling and lead to other more significant problems – See smoke at startup above. Generally the likely issue is caused by the coolant and oil swapping places through the oil cooler. The result is oil in the coolant and worse, coolant in the oil. The majority of the weight is supported by the floor jack: the jack stands are there for backup and for balancing (green arrows). Pull off the cap and use a turkey baster or other suction device to siphon out the fluid in the reservoir. There are many potential causes of a Check Engine Light on the Porsche Cayman and it’s important to read the engine codes or have a repair shop do that for you to assess the faults. A- The compressor is held on by two bolts in the front, and one hidden in the rear (underneath the manifold). If the key fails to open or lock the doors and will not start the car, replace the battery in the key first, paying particular attention to the orientation of the original battery. On older cars these age and become brittle, which can then lead to vacuum leaks (Pelican Technical Article: Throttle Body Replacement / Cleaning Intake & Boots). Assuming the the oil cooler is the issue, it sits beneath the intake and is exchanging heat between oil and coolant at a barrier level. More commonly, a failure in the wire or plug connected to the injector can cause a weak of misfiring cylinder. 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. At one end, the shaft drives the oil pump and at the other, finishes in a sealed bearing. The newer models have the push click lock type of hose connector – no clamps. This means there are more than 73,000 vehicles out there that haven’t had the problem yet or have been retrofit with a newer bearing. Typically, at that point, then engine temp will continue to rise despite the cooling fans running. There are many potential problems associated with this sign – oil could be getting in to the coolant from a blown head gasket, from a crack in the cylinder head, a crack in a cylinder liner or through the oil cooler. Applies to: 1997 Boxster, 1998 The engine was being dropped in preparation to install a brand new 996 3.4L Porsche factory engine in its place (see Pelican Technical Article: Boxster Engine Conversion Project). Water pumps fail regularly. This is where a specialized repair shop can help to quickly and cost effectively get to the route cause of the issue. Often, you wont see the oil initially, as it’s sealed in by the coil on top of the spark plug. Clicking on each heading will give you more detail. With the engine running, observe the pulley and see if there is any sign of wobble. The M97 engines found in the Cayman have variable valve lift and timing. Boxster, 1999 Boxster, 2000 Boxster, 2001 Boxster, 2002 Boxster, 2003 This is commonly seen on Audi engines as well. Typically, an engine that sets faults yet runs well, suggests problems related to emissions control. We recommend inspection of the wiring to the solenoids before replacing them – these can become corroded on older cars due to their location. Keep in mind that you may need to jack up the car higher than you expected in order to remove the engine from underneath the car. Yes, be clear, the IMS bearing is a weak point and it will fail. We recommend you use a battery maintainer any time you store or do not drive the car for an extended period – 2 weeks or more. I would also recommend getting the car's alignment checked when it's back on the road, as this brace is an important rear suspension piece and may affect the alignment settings when removed and then reinstalled. If you have a low-clearance jack (see Pelican Technical Article: Jacking Up and Lifting the Boxster on Jack Stands), you can place your wooden furniture cart (yellow arrow). Now, Porsche is marking 25 years of the mid-engined Porsche Boxster. To get the engine out, put the engine down on a furniture cart, then jacked up the car very high in the air, pulled the engine out, and then lowered the car back down to a workable level. For cars that go to the track on a regular basis, a Porsche Motorsport AOS upgrade is highly recommended. Removing the rear bumper cover can also gain you a few extra inches of working room as well. Either way, how much work is needed is a direct function of the equipment that you have on hand. The only solution here is a replacement engine or rebuild and re-lining of the cylinders. The general rule of thumb is to carefully inspect all the areas and components (lines, vacuum hoses, and electrical connections) that connect the engine with the rest of the car. The housing remains with the engine when you lower it. Typically, an engine that sets faults yet runs well, suggests problems related to emissions control. As the membrane in the AOS fails, oil is sucked into the air intake. Two units matched together – a manual transmission rear section and automated dual clutch front section. (Learn how and when to remove these template ... 291 bhp) 340 N⋅m (250 lbf⋅ft) water-cooled DOHC 24-valve Boxer flat-six (VarioCam Plus) "M97.21" (Cayman S, Cayman S "Porsche Design Edition 1") 2008–2009 3.4 L (3,387 cc) 303 PS (223 kW; 299 bhp) 340 N⋅m (250 lbf⋅ft) water-cooled DOHC 24-valve Boxer flat-six (VarioCam Plus) "M97.22" (Cayman S Sport) VEHICLE ENGINE TYPE MY ENGINE … The manufacturers do not want it taken apart and it’s often described as a “sealed PDK”. Also disconnect the engine ground strap (red arrow). If your Cayman AC system blows warm air, the most common issue is a lack of refrigerant. As you accelerate the engine rpm, the lifter expands to increase valve lift. There are a number of ways in which the PDK in the Cayman can fail. The engine management then shuts off the cylinder until the fault is cleared. Der Sportwagen wurde auf der Beijing Motor Show im April 2016 der Öffentlichkeit vorgestellt. In many cases, even with the head off the engine, the worst scoring cannot be seen until the piston is removed – it can be way down at the bottom of the cylinder. Sales of the 718 are low (less than 4000 vehicles in 2019), so the number of common problems reported at this stage is low. The Mechatronic unit is a common failure point for this type of transmission. Remove Vin W/O Images [7] Days in Market . The rubber seals between the plastic part and the engine block degrade to produce a minor coolant leak down the front side of the engine. Porsche: How to Clean Your Engine Bay. Scanned the car and not sure what to make of those OBD codes? 718 Cayman GT4: Fuel consumption combined 10.9 l/100 km; CO2 emissions combined 249 g/km The high-revving, high-performance and efficient heart of the new Porsche 718 Cayman GT4 and 718 Spyder is a specially developed six-cylinder 4.0-litre boxer engine with lots of high-tech GT genes. Different years will vary in what you need to disconnect, but in general, the procedure outlined above and in the photo series should give a clear indication of the steps that need to be followed. The root cause of this issue is open to discussion, however, wear in the piston rings and liners causes the piston to wobble. Even the most enthusiastic counting of IMS failures produces a total around 3500 or less than 5%. Engine / Motor For Porsche Cayman 2.7L MT Runs Nice 32K (Fits: Porsche Cayman) $7,344.99. 8. Diagnosing the problem often requires multiple steps. Disconnect these only when you have really good ventilation and are able to dissipate the fumes. You certainly don't want to be replacing the air conditioning hoses in your car because they accidentally got damaged during an engine drop. The orange arrow shows the right side compressor bolt. The Porsche Boxster and Cayman are mid-engine two-seater sports cars manufactured and marketed by German automobile manufacturer Porsche across four generations — as a 2-door, 2-seater roadster (Boxster) and a 3-door, 2-seater fastback coupé (Cayman).. Make sure the battery is disconnected before you do this! An early telltale sign can be one exhaust tailpipe being more sooty black than the other. If you don't have enough clearance, you may need to remove the rear axle support bar and pull the engine out the back. The gradual over-heating of the engine that can occur because of a cylinder liner crack, can take some time to appear. The flywheel seal, which can often leak, should be replaced as well (Pelican Technical Article: Clutch Replacement). A crack in the cylinder liner of a Cayman engine can show up in a number of ways from coolant consumption, loss of compression to oil consumption. The bearing in the water pump supporting the shaft wears and the shaft starts to wobble. This causes the engine management to adjust fuel mixtures using a set of parameters which were likely set too broadly by Porsche initially. The tight enclosure of the engine compartment makes it pretty difficult to reach in and access a lot of the fuel injection components. This problem can be solved by replacing the lifters on the particular cylinder on which the fault occurs – although replacing all the lifters on that particular bank, whilst expensive, is probably the recommended solution. However, the problem did not go away and has re-occurred on the same transmissions further down the road. This can very quickly lead to a flat battery. If this happens, use the following procedure: Oil mixed in the coolant can quickly look like peanut butter in the coolant reservoir. It's also a good time to disconnect the oil filler neck (yellow arrow). Replace the clutch and flywheel seal. Shown here is the secondary air injection pump. If in doubt, the work to replace it is quite simple and should be considered a 40K or 4 year item of preventative maintenance. In these cases, the only thing to do is to remove the engine: a task that many conceive to be very difficult. Under worst circumstances this could be a sign of a cracked cylinder liner. Like on earlier Porsches, you leave the compressor in the car when removing the engine. The Boxster engine is not one of the easiest to perform repairs on. The temp sensor problem can show up on almost any model with a PDK. However, we have diagnosed and fixed this issue on a number of Cayman engines. Physically, the PDK is a ZF transmission unit that has been around for a number of years. In general, the Porsche Cayman has a pretty reliable cooling system. Most issues occur with the electronic and hydraulically controlled clutch section at the front of the transmission. Using this method, we did not have to remove the chassis support brace (yellow arrow). It also may be useful to remove the rear bumper to gain additional clearance to pull the engine out from underneath. We recommend cleaning the radiator areas regularly or adding aftermarket screens to the front of the openings to reduce the problem. Porsche Boxter (Boxter 986/987) Technical Forum Message Board. The only resolution is an engine rebuild with replacement liners or a replacement engine. Although you can access them underneath the car, it's much easier to do so with the engine out (Pelican Technical Article: Replacing Spark Plugs and Coils). Of course, that number excludes the cars driven into a ditch, wrapped around a lamp post, rolled off a cliff or set fire too, but you get the point. 4526 Entrerprise Street Fremont, CA 94538 Der 987c ist die erste produzierte Cayman-Generation. Out of the crisis with a brilliant idea. The engine of 2007 Porsche Cayman is placed at the middle to enhance stability when the car is moving at high speed. Porsche adapted the software and labeled their version PDK. This develops into a knocking noise sometimes accompanied by a coolant leak. At that point, it is clear what needs to be done. During any down period the Cayman will continue to use some battery power – in Porsche’s case, usually more than would be expected from similar vehicles. This engine is closely related to the 414 hp variant used in the 718 Spyder and the 718 Cayman GT4. If after replacing the cooler, you need to go to the next stage, having a new oil cooler is not the end of the world and at least eliminates the cooler as the source immediately. > Porsche 987 Cayman (2006-2011) Technical Articles > Engine Air Filter Replacement Pelican Technical Article: Engine Air Filter Replacement Steve Vernon. The early M97 engines fitted to the 987 Cayman can have issues with a bearing at one end of the engine intermediate shaft. So, being forced to lash out $12K to $15K for a new PDK, in our mind, is often caused by an unwillingness of people to take the thing apart! In this situation, we chose to simply drop the engine and exhaust together since the exhaust was filled with coolant and oil from this blown up motor. The Porsche Cayman has a number of common sources for leaking oil. VAG took multiple versions of the transmission and personalized them for their various car ranges. Remove accelerator cable linkage cover, disconnect cable and remove cable linkage assembly from chassis (1997-99 only, Detach both supply and return fuel lines (return line was used only on early cars, see. The Porsche flat 6 engine has a two-stage intake lifter that fails. Coolant in the oil is a quick way to needing a new engine, so it’s critical to diagnose this problem asap. Normal servicing requires the plugs to be changed at 30K mile intervals. Some car owners simply spray the engine bay once or twice a year, while others do a bit more deep cleaning. The original coils were prone to cracking and were replaced by a more substantial version. If left alone, the lifter can stick causing a permanent misfire or worse. These are easy to get on and off but have a nasty habit of being one-time use. 2008 PORSCHE CAYMAN 2.7L ENGINE MOTOR WITH 67,560 MILES COMES WITH ACCESSORIES (Fits: Porsche Cayman) $5,694.89. You need to disconnect the engine wire harness from the DME (green arrow) and the chassis harness (red arrows). Finally, push in the big grommet and stuff the entire wire harness through the big hole in the firewall and place it neatly on top of the engine (purple arrow). The smoke at startup can also be caused by a bad air oil separator (AOS) that has not completely failed yet. In general, I don't suggest letting the engine weight rest entirely on the exhaust headers: the resulting force can put a lot of stress on the threads of the bolts that attach the headers to the cylinder head. Some of the most common include rear main seal (see below), valve covers, spark plug seals and oil cooler seals. How to remove your front/interior engine cover on a 987 Porsche Cayman. The following procedure checklist outlines what you need to do in order to drop the engine: If you follow the procedure carefully, and check/double-check to make sure that everything is disconnected, the actual process of lowering the engine is not difficult. Be sure to reinstall this support brace if you put the car back down on its wheels at some point thereafter (with or without the engine installed). The Porsche flat 6 engine (in particular the M96) has a two-stage intake lifter that fails. Car engines (and the surrounding areas) take a lot of use and abuse. Consequently, below 3K rpm the engine now runs rough until the fault is cleared. 10 Prozent (Cayman S) höheren Preis sowie einer um 10 PS gesteigerten Leistung gegenüber de… Crankcase vacuum exceeds the normal range in the engine under heavy acceleration and sucks in air damaging the rear main seal. The problem can also be set in a number of ways. ), but many major operations need better access. Extended smoking at startup is more of an issue. It is quite common to lower the engine all the way down to the ground, only to find that you need to raise the car much higher to pull it out from underneath.
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