3.4L Swap Underway

[tholyoak]

Here is the 3.4L with the mount and oil pump from the 2.5L engine

As mentioned above if you are lucky and your 996 engine has the boss, you will only need to swap the cap and water outlet indicated by the arrows.

If anyone is interested the TPC supercharger kit is available for $2800 with instructions, and the 2.5L less injection, oil pump and exhuast is available for $2k.

Todd

[Cold Warrior]

Do you have any pics you could share (post or e-mail) of the SC mounted on the 2.5 out of the engine bay?

CW

[tholyoak]

Do  you have any pics you could share (post or e-mail) of the SC mounted on the 2.5 out of the engine bay?

CW

<{POST_SNAPBACK}>

CW,

I will get the old motor mounted on a stand this weekend and bolt the supercharger setup back on so I can take some pics and post them. When I removed the engine I removed the supercharger setup first, so I don't have any pics from the engine removal

Just thought I would share a couple pics of the completed installation:

Todd

[tholyoak]

Ok, I set up the supercharger setup on the removed engine. Not all bolted up but these pics should give you the idea of the layout of the components.

Check out the pics here:

http://members.rennlist.com/tholyoak/DSCF0009.JPG

http://members.rennlist.com/tholyoak/DSCF0010.JPG

http://members.rennlist.com/tholyoak/DSCF0011.JPG

http://members.rennlist.com/tholyoak/DSCF0012.JPG

http://members.rennlist.com/tholyoak/DSCF0013.JPG

Todd

[Cold Warrior]

Ok, I set  up the supercharger setup on the removed engine.  Not all bolted up but these pics should give you the idea of the layout of the components.

Check out the pics here:

http://members.rennlist.com/tholyoak/DSCF0009.JPG

http://members.rennlist.com/tholyoak/DSCF0010.JPG

http://members.rennlist.com/tholyoak/DSCF0011.JPG

http://members.rennlist.com/tholyoak/DSCF0012.JPG

http://members.rennlist.com/tholyoak/DSCF0013.JPG

Todd

<{POST_SNAPBACK}>

Thanks a lot Todd, these will help bif time. How is the 3.4? Any tickets yet? :D

CW

[Monster Boxster]

:) Completed the engine change mid last year, 2000 Boxster 2.7L to 3.4L, E-gas. Had debug issues with the intake, if you have problems I will be happy to relate the issues and solutions.

Best regards,

Larry

[Tool Pants]

The local group met Larry and the monster boxster a few months ago at a tech session put on by Tim Benson at Fast Lane Porsche in Santa Cruz. http://www.renntech.org/forums/index.php?s...3159&hl=monster

Larry showed me some pictures of the intake he had made.

[Monster Boxster]

The local group met Larry and the monster boxster a few months ago at a tech session put on by Tim Benson at Fast Lane Porsche in Santa Cruz.  http://www.renntech.org/forums/index.php?s...3159&hl=monster

Larry showed me some pictures of the intake he had made.

<{POST_SNAPBACK}>

Hi Tool Pants,

The intake has had several major changes since that picture.

Best,

Larry

[tholyoak]

Larry,

Thanks for the offer. Right now I don't seem to have any troubles using 3.5" silicone air duct to connect the TB and the MAF. This is after about 80 miles of driving though, so time will tell. What I would like to do is cut up a stock tube using the ends to hook to the MAF and TB and connected with the silicone duct. Unfortunately my stock tube was discarded when the supercharger was added. Right now my bottle neck is that I am still running the stock headers and exhaust. Need to get my order in for some headers and high flow cats and muffler.

If there is interest I have a writeup of a 'how to' procedure that I could make available. It is still in preliminary stages but gives the basics. It doesn't explain how to remove the engine as that is well documented in the factory manuals but explains the things that need to be done in order to stick a 3.4 into a '99 boxster.

It is kind of big (the pdf is ~60 mb)

Todd

Edited June 5, 2005 by tholyoak

[Monster Boxster]

Larry,

Thanks for the offer.  Right now I don't seem to have any troubles using 3.5" silicone air duct to connect the TB and the MAF.  This is after about 80 miles of driving though, so time will tell.  What I would like to do is cut up a stock tube using the ends to hook to the MAF and TB and connected with the silicone duct. Unfortunately my stock tube was discarded when the supercharger was added.  Right now my bottle neck is that I am still running the stock headers and exhaust.  Need to get my order in for some headers and high flow cats and muffler.

If there is interest I have a writeup of a 'how to' procedure that I could make available.  It is still in preliminary stages but gives the basics.  It doesn't explain how to remove the engine as that is well documented in the factory manuals but explains the things that need to be done in order to stick a 3.4 into a '99 boxster.

It is kind of big (the pdf is ~60 mb)

Todd

<{POST_SNAPBACK}>

Hi Todd,

Sounds like you have everything covered, good job.

Best, 

Larry

[98Boxster98]

If there is interest I have a writeup of a 'how to' procedure that I could make available.  It is still in preliminary stages but gives the basics.  It doesn't explain how to remove the engine as that is well documented in the factory manuals but explains the things that need to be done in order to stick a 3.4 into a '99 boxster.

It is kind of big (the pdf is ~60 mb)

Todd

<{POST_SNAPBACK}>

Todd:

I'm interested in your write-up of your install when you're finished and await your impressions of changes in the driving experience. Thanks for updates of your experience doing the work. It makes for good reading.

[Jinster]

Many people will be interested in the 3.4-swap how-to, Todd. It's not often that a project of this magnitude is undertaken at home. We await your posting of the write-up. (drum roll..........) :)

[Stefan]

I'm definitely interested in such a write-up.

[tholyoak]

OK, the preliminary write up can be found here:

http://members.rennlist.com/tholyoak/34swap.pdf

A big thanks to Steve Wilwerding for compressing the pdf file to a manageable size.

I will hopefully update this when I get some time, but feel free to contact me with questions and comments.

Thanks

Todd

[98Boxster98]

Thanks for taking time for creating the write-up, Todd, pictures and all. It's a great contribution to the DIY community. I'm glad you're going with the Instant-G headers and exhaust - I've been interested in them and I look forward to hearing when you have them installed.

Edited June 7, 2005 by 98Boxster98

[tholyoak]

Well actually Steve has had problems with his fabricator and I don't believe he will be making them again anytime soon, if at all. So it looks like I will be looking at other options for my header/exhaust solution.

Todd

[Jinster]

Thank you for the write-up Todd. Very good read. Gives hope to the rest of us 2.5L anaemics. Once all the parts were there, how many hours, including taking out the old engine, replacing all the opportunistic bits in the new engine, adapting and installing everything, mucking around and procrastinating, did the entire process take? Any specialist "Porsche only" tools required during the process?

[tholyoak]

Jin,

I didn't replace the RMS or the IMS on the car since neither had signs of leaking I let them be. If you were to replace these seals you would need the appropriate factory tools. You need a clutch alignment tool but these are found just about everywhere, not Porsche specific.

I started Friday night for a couple of hours, then worked Sat, and Sunday and was done on Sunday except for the brain reprogramming. it would have been quicker if I had done it before. I raised and lowered the engine several times to see what size spacers I would need. Originally had the 986 fuel rails installed but didn't like that setup so lowered it again and removed the intake to replace the fuel rails. Then needed to fab some fuel lines to work with the 996 rails. Then found I couldn't get the AC compressor installed so removed the intake again. Then found the fuel return fitting on the 996 rails was interfering with the airbox, so modified that. You get the picture. With the knowledge I have now I'm pretty sure I could do it in a day.

Todd

[Richie_007_1968]

OK, the preliminary write up can be found here:

http://members.rennlist.com/tholyoak/34swap.pdf

A big thanks to Steve Wilwerding for compressing the pdf file to a manageable size.

I will hopefully update this when I get some time, but feel free to contact me with questions and comments.

Thanks

Todd

<{POST_SNAPBACK}>

Thank you for the great job on the documentation! I appreciate the great read for my own future project!

Richard

[ljd-924SE]

many thanks for the write-up. i expect to see more and more of these swaps as 986 warranties expire. you've made a priceless contribution to the porsche community.

[al986]

i second that. hear hear!

many thanks for the write-up.  i expect to see more and more of these swaps as 986 warranties expire.  you've made a priceless contribution to the porsche community.

<{POST_SNAPBACK}>

[Stefan]

Out of curiosity, did you happen to weigh the two engines as a comparison?

[tholyoak]

The two engines are essentially identical with the exception of the second plenum on the intake manifold, so while I didn't weigh them, I can assure you there is no significant difference in weight. The 996 engine may even be a tad lighter since you have a larger bore. Overall you will actually loose weight by upgrading the heavy exhaust and muffler with performance parts.

Todd

[natzee]

Todd,

This is great post :clapping: . I have a 97 and thinking about the upgrade. However, I don't have "PSM" (porsche stability management) or traction control as an option of my97.

My concern is all the extra ponies on the upgrade on a car that does not have "PSM" can be a scary experience :jump: .

I am just wondering if you boxster has the "PSM" added to handle the power.

:cheers:

-Nat

[tholyoak]

Nat,

No I don't have PSM or TC. One of the reasons I wanted an earlier car, in order to avoid the electronic controls. People got by just fine for decades without PSM or TC, they simply learned how to drive, or they crashed :)

Seriously the Boxster chassis is quite capable, and can easily deal with the increase in power. Obvioulsy if you look at the evolution of the car now with the Cayman coming with a 3.4L, Porsche obviously designed the car to be able to cope with the power.

Todd