996 45k Service

Knocked out a 45k service on a 996 a few days ago. It is a pretty basic service in between the major services. It includes changing filters, oil change, and a full inspection. Read the dme down to make sure there are not any pending codes, etc. The next major will be at 60k which will be more involved with spark plugs being changed out. EvoMS intake. The filter needs to be removed and cleaned out. Easiest to take the …

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996 Oil Leaks

A buddy of mine brought by his 996 that is having trouble containing it’s oil, lol. Every time he drives the car, he gets out and smells that familiar smell of oil burning off the engine. It was time to get it taken care of. One of the most common sources of oil leaks in the M96 motors are the spark plug tube seals. There is an inner and outer o ring on the tube that will leak over time. …

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Awhile back I had written a post about window drop issues in the boxster/996. A few weeks ago I had a Boxster come in for an oil change, and a window that was not functioning properly. The driver window would not drop at all, from the inside door handle, or the outside door handle. To me, this said that the microswitch on the latch mechanism always thought the door was closed. So I ordered a new latch. Today I knocked …

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It was a nice feeling to get go through this and fix the “things” that have happened since I last saw it. Old O2 sensor unscrewed. Yuck. Now to get to the electrical connector. Remove the outer intake pipe. Then the charge cooler comes out of the way. Once I got in there, I found one of the pipes was disconnected. Funny thing is, my old paint marks are still on the pipes from where the hose coupler should properly …

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996 Spark Plugs

Threw in new spark plugs today. Garage is pretty much shut down for the next 7 days while the new epoxy floor cures, so had to knock it out in the driveway. Eeeek. Remove the outer heat shield. And it exposes the coil packs. Remove the coil packs and you can get to the plugs. They were pretty nasty looking! Tomorrow I should have the MAF, O2 sensor, and the ignition switch and this thing should be out the door!

Life has not been kind to you. We can change that though! A lot of dash lights on, with an intermittent CEL. Lot of history with this car. Though I haven’t seen the car in years, this is the car that started it all for me. Back when I was young pup (ok, I still am….suckas!), I was finishing up my postceptorship for my D.C. degree working for another chiropractor in town. I was working there during the day, and …

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This problem has been popping up on a very regular basis on the Boxster and 996 engines.  So much, that I think I am going to start recommending waterpump replacement at about the 80k mile or 10 year mark as that is about when they seem to be failing. Failure can be leakage from the bearing weep hole, and if that is let go for more than a few days, the bearing and impeller are going to explode. Not a pretty sight. We …

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We finally got some semi warm weather (almost hit 40 today!), so I took the opportunity after lunch to run out and pull some mufflers for a buddy that we are going to modify 🙂  The OEM (Non-PSE) mufflers are just too mild, so we are going to have to fix that.  Got the unit open after chopping the door pull free from the ice. Up in the air and ready to pull the mufflers. Passenger side can stuck up …

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996 Continued

After looking into a coolant light issue, we found the coolant tank was pretty much empty. The tanks are prone to cracking in the 996’s, usually along the backside or bottom near the level sensor. They aren’t a ton of fun to get out, not difficult, but it takes some manipulation to get it angled just right to come out. When you replace the tank you want to also install an updated radiator cap (black vs. the original blue cap). …

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996 Maintenance

Had a freind bring by his 996 for some winter maintenance. This was actually the Evolution motorsports prototype car for their supercharger kit they developed with VF Engineering. First thing to do was to replace the ignition switch. The 996 and boxster are notorious for having bad ignition switches. It can rear it’s head in many different ways. 1. Key switch that is difficult to turn or seems to hang up 2. Key that rotates way more than it should …

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