Hydraulic Cam Adjuster Problem

[busa_4]

yes, the solenoid is bad. before you start this repair, you will need to purchase special silicone sealant from a porsche parts dealer. do not use regular sealant from the parts store. the sealant is the only form of gasket for the cam cover. there is no paper gasket in between. also you will need to purchase all the seals and o-rings to do the job correctly. good luck!

[mikevv]

OK. I priced the parts at two local dealers and it looks like just under $1000 for everything. The vario actuator being just over $700. Although the actuator electronics can be purchased separately for $230. They tell me that on a 97 Boxster, you have to use two special tools to hold the cam in place so you can remove the oil pump to get at the actuator. Does this make sense to you?

[busa_4]

no no no no! you dont need the actuator, you only need the solenoid.
i work at a porsche dealer and i got the part number for you.
the part number is 99660590100 and it sells for 185.00
remember to get the seals and sealant.

[busa_4]

oh yeah i forget there is a tool to hold the cam in place so you dont break them when removing the camcover. you will need to purchase this tool. dont attempt this repair without the tool. there is a guarantee that you will break the cams if you dont have it. the oil pump they say is an oil pump is actually a oil scavenge pump. the oil scavenge pump has to go on the same way it came off. it can be reversed so make a mark on the scavenge pump and the engine block so you put it in the correct position.

[mikevv]

OK
I think I have it now. Do you have a part number for the tool? And what do you think about the misfire codes?

[busa_4]

the dealer will be able to supply you with the tool part number. the misfire codes are because bank 1-3 are not in timing because the solenoid has failed. that solenoid passes oil pressure through the cam actuator. when there is pressure to the actuator is rotates the intake cam ~12 degrees retarded to gain more hp.

[mikevv]

Busa_4
What I really should do is take a weeks vacation in Florida and have your dealership fix it. My two local dealers are border-line rude when I try to get information on the problem, the fix and the parts I need. I would probably pay them to fix it if they were willing to work with me on it.

If the parts are say $700 and they want $2200 to fix it they are either making a lot of money or are going to take over three days to do the work that you can do in 3hours.

Thanks for all the advice.

[busa_4]

what parts are they trying to sell you for 700.00? if you know how to weld you can make the tool. it is a very basic tool.

[mikevv]

Solenoid $235, 12cam housing bolts $11, Spark plug seals $60, Sealant $51, Oil Pump O-ring $21, Solenoid seal $30, for about $400. That was the low end. The other dealer had higher prices and added a couple seals I didn't understand.

I can weld and will see if I can find a picture of the tool on the web.

Thanks as usual.

MikeV

[busa_4]

Why Are The Prices So High Over There?

[mikevv]

Well I guess I don't know. There are two local dealers in Columbus, Ohio and I don't have anything else to compare to. Is there any way I can buy the parts from your dealership? If you give me a name and number of your parts person I'll take it from there.

I will be out of town for the next two weeks so I will probably attack this after Thanksgiving.

[busa_4]

you can give them a call at 813-933-2811. we have 8 car lines so ask for porsche parts.

[mikevv]

Busa_4
I have located a Porsche Technical Repair Manual and it contains pictures of the tools I need for this job. Tool P9624 is a plate thst goes from one cam plug to the other behind the passenger seat. It has a tab where a bolt fastens it to the cyl-head. I assume this holds the cams down while the cam cover is removed. Once the cam cover is off there is another tool P9611 that is a set of 4 clamps to further hold the cams in place. Will I need these clamps if all I am doing is removing the actuator?

The Porsche manual says that the solenoid cannot be replaced unless the whole assembly is vertical. If this is true then I will need to remove the whole assembly which I think involves removing the lower camshaft chain sprocket and perhaps loosening the upper camshaft itself? Can you provide a little guidance here.

Thanks as usual

Mikevv

PS With the info you have provided I was able to get the local dealer to order the solenoid only. They will also sell me the tools if I need them.

[busa_4]

all you need is that cam hold down tool. you dont have to remove the cams. unbolt the solenoid, replace it and your done. if you get stuck in the middle of it just email me back and i will walk(type) you through it.

[mikevv]

Busa_4
We have a go! I drove the Boxster 30 miles tonight (in
the snow I might add) and it didn't generate any
codes. I am so excited. It idles much better now also,
drops down to 900rpm and stays there rock steady.

I can't thank you enough for your expert advice,
patience and confidence. I doubt I would have tackled
this without your help. I am just sorry I waited so
long to do the work. Lost another summer! Well anyway
we have next summer to look forward to now.

Have a wonderful holiday season and a great new year.

MikeV