99 Boxster 2.5L with 80K miles
I'm rebuilding the engine and right now it is all apart. I am replacing bearings, oil squirters, timing chains and guides, valve stem guides, rod wrist pin bushings, valve springs, lifters (but not the cages), IMS bearing, crankshaft seals, AOS system, water pump, thermostat (low temperature), fuel pressure regulator, 5-speed transmission main shaft seal, and all the necessary gasket kits, bolts, etc. I am replacing the exhaust system with a high-performance system with headers.
The main engine block parts have been ultrasonically cleaned. The heads have been partially ported and the valves have been cleaned and reseated. The injectors were tested and found OK. They were cleaned and will be reused with new tips and O-rings. The crank has been mag tested for cracks and the runout checked. Everything is OK. I just finished a detailed check of the cylinders and heads for cracks using both a handheld 800x magnifier and dye penetrant. Nothing was detected and there is no scoring of the cylinder walls. I haven't checked the bores yet, but I suppose I will after I obtain a decent bore measurement device.
The pistons appear to be in very good condition and show (from my limited experience) minimal wear. Right now, I am deciding if I should replace the rings. They do show scoring across the outer edge and that may reduce the rings effectiveness at forming a good contact with the cylinder wall. One problem I am having is the ring suppliers do not want to provide gapping requirements with their product. As far as I am concerned, this information should be an integral part of the product. This seems to be a modern trend with suppliers. So many of them do not want to provide the purchaser with adequate information about their product. What do you people think, should I replace the rings?
I also found a hole plugged with a pin set flush with the bottom of each center ring grove. Does anyone know what this is?
I am NOT replacing the timing chain tensioners or the vario-cam solenoids. I feel if they start to fail, I will have adequate notice and I can change them without dropping the engine.
Please chime in on any of this. Maybe there are other things I should be looking at or changing while the engine is open.
