Info re 3.4l engine swap please?

[PleGrange]

Gentlemen and Ladies.

My 3.4l engine is on it's way from the USA to South Africa for my MY97 Boxster!!!!

A few questions please?

1) Best clutch to use?

2) Any gaskets that I must pre-order so that the swap can be done without to much standing time?

Let me see:

1)I have somebody with PS2 to programme my DME. (spare DME comes with engine with programming codes)

2)Have spare harness so that I can get the pin for the extra wire to the resonnance valve.

3)Have 1 week leave to do the swap.

4)Have clean overall.

Have I forgotten anything?

Regards

Pieter

1997 2.5l Boxster (soon to be 3.4l)

5 speed Manual

Guards Red

[savowood]

1) Best clutch to use?

SPEC

http://www.specclutch.com/

It's stronger and has a much lighter feel than the stock clutch.

[PleGrange]

Hi Michael,

Thanks for the reply and the website link.

I am really considering the stage 3 clutch as it is the same price as the stage 2. Why would the stage 2+ be more expensive?

(i see that you recommend the 2+)

(I read what the Spec Clutch website says but all I could interpret were that they were all good!)

Should I buy the 996 clutch or the Boxster's? I guess the Boxster's as the flywheel is on the engine?

Should I fit a light weight flywheel?

Does my Boxster have a Dual mass flywheel?

Regards

Pieter

[PleGrange]

Hi Michael,

Thanks for the reply and the website link.

I am really considering the stage 3 clutch as it is the same price as the stage 2. Why would the stage 2+ be more expensive?

(i see that you recommend the 2+)

(I read what the Spec Clutch website says but all I could interpret were that they were all good!)

Should I buy the 996 clutch or the Boxster's? I guess the Boxster's as the flywheel is on the engine?

Should I fit a light weight flywheel?

Does my Boxster have a Dual mass flywheel?

Regards

Pieter

Hi Michael,

I contacted Spec cluth via e-mail and had no reply. Is this usual or do I just have to keep on e-mailing them?

Regards

Pieter

[catmanluge]

I had good results with Spec. The Boxster clutch is the only one that will fit in the Boxster transmission bellhousing. I would go with the stage 3 if you plan to track the car other wise stage 2 is fine. If you go to a light weight flywheel be careful as some require machining if you use a sprung disk. As the stock type bolts will not fit..

Hi Michael,

Thanks for the reply and the website link.

I am really considering the stage 3 clutch as it is the same price as the stage 2. Why would the stage 2+ be more expensive?

(i see that you recommend the 2+)

(I read what the Spec Clutch website says but all I could interpret were that they were all good!)

Should I buy the 996 clutch or the Boxster's? I guess the Boxster's as the flywheel is on the engine?

Should I fit a light weight flywheel?

Does my Boxster have a Dual mass flywheel?

Regards

Pieter

Hi Michael,

I contacted Spec cluth via e-mail and had no reply. Is this usual or do I just have to keep on e-mailing them?

Regards

Pieter

[qikqbn]

Gentlemen and Ladies.

My 3.4l engine is on it's way from the USA to South Africa for my MY97 Boxster!!!!

A few questions please?

1) Best clutch to use?

2) Any gaskets that I must pre-order so that the swap can be done without to much standing time?

Let me see:

1)I have somebody with PS2 to programme my DME. (spare DME comes with engine with programming codes)

2)Have spare harness so that I can get the pin for the extra wire to the resonnance valve.

3)Have 1 week leave to do the swap.

4)Have clean overall.

Have I forgotten anything?

Regards

Pieter

1997 2.5l Boxster (soon to be 3.4l)

5 speed Manual

Guards Red

Hey Pieter,

Congratulations on your conversion to 3.4. A few things I would recommend while you have the motor out...

1. Change the RMS (rear main seal) to the latest offered by porsche for the 3.4...

Porsche has upgraded and made this part better several times now. Get the latest and greatest.

2. Depending on how old your plastic Coolant resevoir container is. I would replace it.

early boxsters and 996's had problems with these cracking when they get old. I had replaced

mine once with the 2.5 motor and then replaced it again just to be safe when I put in the 3.4

since they run a little bit hotter.

3. Change out your flywheel as well. depending on your mileage it may be a good idea.

I replaced my clutch with the 987 boxster part number and have had no problems getting

325 hp to the ground. But unless you drag race all the time, then you will want something

stronger. get a new pilot and throw out bearing. Flush your clutch fluids..

4. change your motor mounts if they look tired. you will be dealing with a lot more torque under hard accelleration

and engine breaking.

5. Very IMPORTANT. Install a hi flow intake if you want proper performance. The boxster airbox is

too small... You also must have a MAF housing tube that is 3.5 inches like the stock 996

or if you use the boxster 3 inch maf housing then you will need to modify or "callibrate" your

voltage signal for your 996 ECU to apply the proper fuel maps or else it will run very rich.....see this thread

it explains a lot on proper MAF signal: 20-30 hp difference.

http://www.renntech.org/forums/index.php?s...mp;#entry125122

6. If you live in a very hot environment then a center radiator may be a good idea, but then you would

need an opening in your front bumper for air flow as well. this is optional...

7. replace any coolant hoses that look dried out or brittle.

8. If you plan on tracking the car there is an "oil baffle" made for the 2001 and new engines.

This keeps oil from sloshing around so much during hard cornering and causing oil starvation..

If you have a 1999 3.4 engine then it may not have this baffle in it..

9. make sure to get your key reprogrammed as well to work with the 996 ecu and alarm system.

10. Think about also replacing the Air Oil separator.. much easier to do while engine is out and these

do go bad depending on mileage.

Best of luck.... If done properly you will be very happy!

Bill

Edited March 26, 2009 by qikqbn

[PleGrange]

Hi catmanluge,

Thanks for the reply.

They still havent responded to my e-mails, so I have no idea on how much it is going to cost.

I am not planning on putting the car on the track. Only perhaps the few times now and then on club days at the track.

Is the stage 3 clutch very difficult to drive in traffic?

I think I will keep my flywheel as is?

Regards

Pieter

I had good results with Spec. The Boxster clutch is the only one that will fit in the Boxster transmission bellhousing. I would go with the stage 3 if you plan to track the car other wise stage 2 is fine. If you go to a light weight flywheel be careful as some require machining if you use a sprung disk. As the stock type bolts will not fit..

Hi Michael,

Thanks for the reply and the website link.

I am really considering the stage 3 clutch as it is the same price as the stage 2. Why would the stage 2+ be more expensive?

(i see that you recommend the 2+)

(I read what the Spec Clutch website says but all I could interpret were that they were all good!)

Should I buy the 996 clutch or the Boxster's? I guess the Boxster's as the flywheel is on the engine?

Should I fit a light weight flywheel?

Does my Boxster have a Dual mass flywheel?

Regards

Pieter

Hi Michael,

I contacted Spec cluth via e-mail and had no reply. Is this usual or do I just have to keep on e-mailing them?

Regards

Pieter

[PleGrange]

Hi qikgbn,

Thanks for your best wishes and your very much appreciated advice. I cannot wait for my engine to arrive.

1)I will check tehe RMS, hopefully it is still the old one and I can replace it easily.

2)I have replaced my coollant bottle recently. (2nd time) It seems that they only last about 100k km's. My car has done 208k km's now.

3)My clutch is my biggest worry at this stage. I will look into the cost of the 987 clutch, in SA it is very expensive. I'm not really into the drag racing thing, just do not want these kids in their street racers to out accelerate me.... lol.

4)I will make sure that tmy motor mounts are in tip top condition. I do not want the engine to fall out the back.

5) I will install a hi flow intake.

6) I am going to first run the car with the normal radiators. If additional cooling is required I will install the 996 bumper with the extra radiator.

7) New radiator hoses it will be.

8) No racing for me. I will check into the cost of the baffles, and if not to expensive I will install baffles.

9) Porsche South Africa have aggreed to do all the programing of the DME that is coming with the engine, they have access to the required security codes for the security system.

10) I will also look into the air/oil seperator cost and again if not to expensive I will replace it.

Thank you very much for your interst and suggestions. I appreciate it very much.

Regards

Pieter

Gentlemen and Ladies.

My 3.4l engine is on it's way from the USA to South Africa for my MY97 Boxster!!!!

A few questions please?

1) Best clutch to use?

2) Any gaskets that I must pre-order so that the swap can be done without to much standing time?

Let me see:

1)I have somebody with PS2 to programme my DME. (spare DME comes with engine with programming codes)

2)Have spare harness so that I can get the pin for the extra wire to the resonnance valve.

3)Have 1 week leave to do the swap.

4)Have clean overall.

Have I forgotten anything?

Regards

Pieter

1997 2.5l Boxster (soon to be 3.4l)

5 speed Manual

Guards Red

Hey Pieter,

Congratulations on your conversion to 3.4. A few things I would recommend while you have the motor out...

1. Change the RMS (rear main seal) to the latest offered by porsche for the 3.4...

Porsche has upgraded and made this part better several times now. Get the latest and greatest.

2. Depending on how old your plastic Coolant resevoir container is. I would replace it.

early boxsters and 996's had problems with these cracking when they get old. I had replaced

mine once with the 2.5 motor and then replaced it again just to be safe when I put in the 3.4

since they run a little bit hotter.

3. Change out your flywheel as well. depending on your mileage it may be a good idea.

I replaced my clutch with the 987 boxster part number and have had no problems getting

325 hp to the ground. But unless you drag race all the time, then you will want something

stronger. get a new pilot and throw out bearing. Flush your clutch fluids..

4. change your motor mounts if they look tired. you will be dealing with a lot more torque under hard accelleration

and engine breaking.

5. Very IMPORTANT. Install a hi flow intake if you want proper performance. The boxster airbox is

too small... You also must have a MAF housing tube that is 3.5 inches like the stock 996

or if you use the boxster 3 inch maf housing then you will need to modify or "callibrate" your

voltage signal for your 996 ECU to apply the proper fuel maps or else it will run very rich.....see this thread

it explains a lot on proper MAF signal: 20-30 hp difference.

http://www.renntech.org/forums/index.php?s...mp;#entry125122

6. If you live in a very hot environment then a center radiator may be a good idea, but then you would

need an opening in your front bumper for air flow as well. this is optional...

7. replace any coolant hoses that look dried out or brittle.

8. If you plan on tracking the car there is an "oil baffle" made for the 2001 and new engines.

This keeps oil from sloshing around so much during hard cornering and causing oil starvation..

If you have a 1999 3.4 engine then it may not have this baffle in it..

9. make sure to get your key reprogrammed as well to work with the 996 ecu and alarm system.

10. Think about also replacing the Air Oil separator.. much easier to do while engine is out and these

do go bad depending on mileage.

Best of luck.... If done properly you will be very happy!

Bill

[qikqbn]

Hi qikgbn,

Thanks for your best wishes and your very much appreciated advice. I cannot wait for my engine to arrive.

1)I will check tehe RMS, hopefully it is still the old one and I can replace it easily.

2)I have replaced my coollant bottle recently. (2nd time) It seems that they only last about 100k km's. My car has done 208k km's now.

3)My clutch is my biggest worry at this stage. I will look into the cost of the 987 clutch, in SA it is very expensive. I'm not really into the drag racing thing, just do not want these kids in their street racers to out accelerate me.... lol.

4)I will make sure that tmy motor mounts are in tip top condition. I do not want the engine to fall out the back.

5) I will install a hi flow intake.

6) I am going to first run the car with the normal radiators. If additional cooling is required I will install the 996 bumper with the extra radiator.

7) New radiator hoses it will be.

8) No racing for me. I will check into the cost of the baffles, and if not to expensive I will install baffles.

9) Porsche South Africa have aggreed to do all the programing of the DME that is coming with the engine, they have access to the required security codes for the security system.

10) I will also look into the air/oil seperator cost and again if not to expensive I will replace it.

Thank you very much for your interst and suggestions. I appreciate it very much.

Regards

Pieter

Gentlemen and Ladies.

Have I forgotten anything?

Regards

Pieter

1997 2.5l Boxster (soon to be 3.4l)

5 speed Manual

Guards Red

Hey Pieter,

Congratulations on your conversion to 3.4. A few things I would recommend while you have the motor out...

Best of luck.... If done properly you will be very happy!

Bill

Hi Pieter,

No problem. I know how stressful and exciting an engine swap can be. Stressful because you want everything to go smoothly, run properly, and last long.

Depending on the motor, programming, and your bolt on additions like exhaust and intake a 3.4 motor can make anywhere from

280 horsepower to 325 hp. So getting the right combination of parts together can make a big difference.

I am not sure if you have access to discount parts like Sunset Imports (800) 346-0182 that may or may not ship overseas, not sure.

but off the top of my head these are some prices I paid approximately... don't quote me though ;^)

best thing to do is call Sunset. They are nice guys over there.

--As far as RMS. The seal part is only around $10-15 dollars. So it is not expensive, but needs to be installed properly

and with care. It will help you sleep better knowing the seal has been updated.

--The clutch disc and pressure plate were around $300-350 dollars from Sunset

ask the parts guy to cross reference the part number for the 986 2.5 5 speed versus

the 987 boxster S.... Maybe the disc part numbers and bolt patterns are the same, ...

I changed mine 3 years ago, so the details are a bit hazey. I have had no problems

with over 20,000 miles and I drive aggressively.

--throw out bearing may be included in clutch kit and the pilot bearing was not that expensive... maybe $20

--the oil baffle was around $30 but needs some Porsche sillicon gasket stuff to reseal the oil case.

--AOS was around $90-100

-- dual mass Flywheel... expensive... like $600-700

-- one more note on the air intake... The hi flow air intake is part of the solution.

The "size" of your MAF housing makes a bigger difference because it relates

a voltage signal to your 996 ecu. Based on the voltage signal the 996 ecu

applies certain fuel maps. It is ok to use the stock boxster maf housing, but

just be aware that using the smaller housing sends a "higher" signal to

the ecu because air has to pass faster through it than a 3.5 inch housing.

This higher signal will change your fuel maps and run rich.

There are easy solutions to this as you may have read already in the post

I gave you earlier. It could be as simple as applying a small resistor to

the maf signal wire. But it makes a big difference in performance.

all the best. keep us updated on your success...

B

[PleGrange]

Thanks Bill,

I am an electronics technician and I will look into the resistor route for the voltage on the MAF signal.

The costs you "mentioned" does not seem to be to expensive and I will be able to do a lot of your suggestions.

All I am waiting on now is the arrival of my engine.

Regards

Pieter

[savowood]

Sorry for the delay...a lot of travel for work lately. I'd call them directly. They really need to talk to you to determine the best clutch for your use.

The clutch I have (I think it's a 2+ but it might be a 3) is VERY easy to drive on the street. It's a lot lighter than the stock clutch, and it's stronger.

-Michael

[PleGrange]

Thanks Michael,

I will phone them, the time difference between Alabama and South Africa is 8 hours and telephone costs are horendously expensive. I guess if I want the best then that is what I will have to do.

Regards

Pieter

Sorry for the delay...a lot of travel for work lately. I'd call them directly. They really need to talk to you to determine the best clutch for your use.

The clutch I have (I think it's a 2+ but it might be a 3) is VERY easy to drive on the street. It's a lot lighter than the stock clutch, and it's stronger.

-Michael

[PleGrange]

Hi Michael,

Just a little feedback and a question

The people from SPEC clutch have returned my e-mails and the SPEC 2+ clutch seems the way to go. The cost is not too expensive.

I am a little confused, Is the 996 flywheel to big to fit in the 2.5l Boxster bellhousing? Therefore I must fit my 2.5l flywheel to the 996 Engine? (or fit the 987 flywheel?)

Regards

Pieter

Sorry for the delay...a lot of travel for work lately. I'd call them directly. They really need to talk to you to determine the best clutch for your use.

The clutch I have (I think it's a 2+ but it might be a 3) is VERY easy to drive on the street. It's a lot lighter than the stock clutch, and it's stronger.

-Michael

[PleGrange]

At last!!!!

The most stress I had in a lifetime for the past 4 months!

From buying an engine kind of blindly... accross the ocean, shipping it via unknown people, to starting this afternoon.... probably the most stupid thing I had done in all my life, but when that engine started this afternoon I felt like a little boy with my first bicycle...

Let it be known: my engine 996 (3.4) started today at 1pm in my 1997 Boxster.

Status:

I started the engine with my existing DME (996.618.601.02) It still has the 2.5 programme in it and I will visit Porsche SA on Wednesday to load the 996 programme. (If the 996.618.601.02 cannot be re-programmed, I have a 996.618.601.04 will see on Wednesday.)

I used a SPEC stage 2 clutch.

The 996 flywheel does not fit with the Boxster 5 speed transmission so I used the Boxster's flywheel. Hope this will do.

I want to thank everybody that so kindly assisted me with information.

Special thanks to:

Tholyoak Todd.. if it wasnt for you I would have never have attempted this. (Sorry for the mistaken identity at one stage and for that I accidently pi@@ed you off.)

Qikqbn Bill... Thanks for your help and assistance.

Loren for your directions...

Renntech for have created this site.

LA Dismantlers... initial not to good experience but eventually goods delivered as promised. I now hold thumbs that the engine is good for a few million miles..

Thanks again everybody.

Pieter

[Guest]

Glad that it worked. Went thru the same stress; my car was ready last week finally to.

Don't worry about Todd. It's very easy to get him pi$$ed for no reason.

Enjoy your car.

Sergiu

[PleGrange]

Thanks Sergiu, good luck with your car too!

lololol.... If it wasnt for Todd I would not have had the guts to do it and prove some of the "Porsche" specialists in South Africa wrong.

I am really thankfull for you lot on this forum with the words of encouragement and advice. I am litterally right at the end of the world, well almost, there is still the Southpole between SA and the end... and everybody here protects their "knowledge" with their lives just to make a buck or two from the rest of us.

I could not even buy a 996 engine here because the "sole importer" buys EVERY crashed car from the insurance companies and keeps them on a farm in a town about 55km from Johannesburg. The cars just stand there.

I can buy a new engine but it will cost me more than $(US) 40 000!!

Just an update about my car:

We wanted to change the security module under the seat, and the DME, with the 996 modules I got with the engine, bad news, the DME fits but the security (USA) module's plug is incompatible with my car's. The the USA module has a blue plug and the module in my car (Euro) has a white plug. The blue plug is slightly narrower and they have different key slots, so the plugs do not fit. I opened the modules and they have completely different circuits inside.

I will get the security codes of both my car and the replacement modules and programme the DME with my car's security codes. Will do that next week.

Otherwise the engine does not leak oil, revs like crazy, no noises, just SWEET power, and this still with the resonance valve not functioning, the revs still limited at 6800 and the 2.5 exhausts!

I must teach my throttle foot not to be so hard on the throttle.... lol.

Regards

Pieter

Glad that it worked. Went thru the same stress; my car was ready last week finally to.

Don't worry about Todd. It's very easy to get him pi$$ed for no reason.

Enjoy your car.

Sergiu

[PleGrange]

Update on 3.4 Installation.

I want to (again) thank everybody that was involved with information, words of wisdome and help.

I installed the third radiator and temperatures NEVER go above 103deg Celcius (217 F) in hot 35deg Celcius (95 F) South African heat as displayed by the centre airconditioning display. Actually, if I keep the airconditioner on the temperature never goes above 96 deg C (204 F).

Before I installed the third radiator the temperature went up to 113 deg C (235 F) before the temperature will go down again to 96 and then go trough the cycle again.

The engine has done 25 000 km (15 534 miles) since the installation. Absolutely no problems. The engine runs perfect. No oil useage, no oil leaks, no noises, no vibrations i.o.w. just like a factory installed engine.

Regards

Pieter

At last!!!!

The most stress I had in a lifetime for the past 4 months!

From buying an engine kind of blindly... accross the ocean, shipping it via unknown people, to starting this afternoon.... probably the most stupid thing I had done in all my life, but when that engine started this afternoon I felt like a little boy with my first bicycle...

Let it be known: my engine 996 (3.4) started today at 1pm in my 1997 Boxster.

Status:

I started the engine with my existing DME (996.618.601.02) It still has the 2.5 programme in it and I will visit Porsche SA on Wednesday to load the 996 programme. (If the 996.618.601.02 cannot be re-programmed, I have a 996.618.601.04 will see on Wednesday.)

I used a SPEC stage 2 clutch.

The 996 flywheel does not fit with the Boxster 5 speed transmission so I used the Boxster's flywheel. Hope this will do.

I want to thank everybody that so kindly assisted me with information.

Special thanks to:

Tholyoak Todd.. if it wasnt for you I would have never have attempted this. (Sorry for the mistaken identity at one stage and for that I accidently pi@@ed you off.)

Qikqbn Bill... Thanks for your help and assistance.

Loren for your directions...

Renntech for have created this site.

LA Dismantlers... initial not to good experience but eventually goods delivered as promised. I now hold thumbs that the engine is good for a few million miles..

Thanks again everybody.

Pieter

[catmanluge]

Update on 3.4 Installation.

I want to (again) thank everybody that was involved with information, words of wisdome and help.

I installed the third radiator and temperatures NEVER go above 103deg Celcius (217 F) in hot 35deg Celcius (95 F) South African heat as displayed by the centre airconditioning display. Actually, if I keep the airconditioner on the temperature never goes above 96 deg C (204 F).

Before I installed the third radiator the temperature went up to 113 deg C (235 F) before the temperature will go down again to 96 and then go trough the cycle again.

The engine has done 25 000 km (15 534 miles) since the installation. Absolutely no problems. The engine runs perfect. No oil useage, no oil leaks, no noises, no vibrations i.o.w. just like a factory installed engine.

Regards

Pieter

At last!!!!

The most stress I had in a lifetime for the past 4 months!

From buying an engine kind of blindly... accross the ocean, shipping it via unknown people, to starting this afternoon.... probably the most stupid thing I had done in all my life, but when that engine started this afternoon I felt like a little boy with my first bicycle...

Let it be known: my engine 996 (3.4) started today at 1pm in my 1997 Boxster.

Status:

I started the engine with my existing DME (996.618.601.02) It still has the 2.5 programme in it and I will visit Porsche SA on Wednesday to load the 996 programme. (If the 996.618.601.02 cannot be re-programmed, I have a 996.618.601.04 will see on Wednesday.)

I used a SPEC stage 2 clutch.

The 996 flywheel does not fit with the Boxster 5 speed transmission so I used the Boxster's flywheel. Hope this will do.

I want to thank everybody that so kindly assisted me with information.

Special thanks to:

Tholyoak Todd.. if it wasnt for you I would have never have attempted this. (Sorry for the mistaken identity at one stage and for that I accidently pi@@ed you off.)

Qikqbn Bill... Thanks for your help and assistance.

Loren for your directions...

Renntech for have created this site.

LA Dismantlers... initial not to good experience but eventually goods delivered as promised. I now hold thumbs that the engine is good for a few million miles..

Thanks again everybody.

Pieter

RE the oil baffle was around $30 but needs some Porsche sillicon gasket stuff to reseal the oil case.

By chance do you havge the part number for the baffle?