ouroboros

Yikes...

997.2 engine? Can you tell us more? How easy was it for a 7.8 DME car?

Todd, Did you ever get to a 3.8 engine? !

Hi,

I got hold of a 03 996 3.6 engine last year but work and other projects prevented me starting this. I'm not 100% sure of the quality of my new donar so I'm going to crank the engine first and do some compression testing while it's still on the crate.

Thereafter someone recommended I could get it tested on an engine dyno stand. Can anyone give me any pointers becuase I'm thinking getting the electronics out to do this is maybe more difficult than testing the new engine in the car. Is there any rudimentary hook up you can do to just get the engine running?

I'm doing this at home I want to try ensure my project is going to work before I drop my perfect 3.2l existing engine.

Cheers!

You boys have any luck with this? I've bought a Benz ML550 and I need to do a hybrid for another reason : Getting a disk that will only work in a US nav unit to have some non US maps. My US map DVD had the same BAS files detailed above.

I'm gong to be buying some Nav DVDs with BAS Navteq file extensions (Honda & Chrysler). Surprised there is no info on the net regarding the structure of these.......

Dug up this old thread after seeing a 987 with an aerokit yesterday. It looked great, like this:

http://www.porscheshop.co.uk/acatalog/info_3194.html

I think this, or the cayman style lip updates the look of the 986 in a nice understated way - What

Porsche has actually done themselves.

The aero discussion in this thread is interesting however and I would want to retain a solid block pop-up spoiler.

Does anyone know if a replacement spoiler exists, like the stock unit (solid block inside) with a lip on the end to look like the cayman?

Cheers

Think that's Voxsters over on the PPBB. I don't like the wheels personally. First bumper is better IMO as the gap style only came out in the 987 generation

It is about time, I will give my 986S a new GT3 lower balance look,,,

I'm wondering if any of U fellas has done the front bumper mod with this GT3 kit?

Any input would be appreciated.

What do you think of this one?

It's one of my favorites, although it could be a little lower!

Regards, Maurice.

Hi Guys,

I need to move an M96 engine from a palette to a trolley. I’ve searched the engine for hoist points but can’t find any other than this one:

I see in the Bentley manual this is used when installing the engine, in conjunction with a support brace and a jack underneath. Guess it’s not good on it’s own for a engine move though.

Otherwise I see Pelican offers this, which seems to screw into the screws at both side of the engine but it's for the watercooled engines I think?

Don’t really want to spend 100 bucks because the engine has no hoist points - Any other suggestions? Good ol ratchet strap?

Or M8 bolts in the three holes at either side, below the fuel rails + ratchet strap?

Jake,

I guess my comment is probably more relevant to the average guy maybe preferring the Porsche recon route to a third party rebuild, which looked around the same price.

But I love your concept of education/parts so you can DIY. And I also accept those that race etc would prefer the engine improvement route - If mine goes I would prefer this route also. I see it's also looking likely the recon supply will dry up.

One issue for alot of the guys not in the US, is that if you are out of warranty it costs alot to ship engines/cores around the world (I shipped a 3.6 from the US to the UAE so I know from experience!). Your concept would surely save us a stack by allowing us to only ship parts where possible.

Absolutely.. I sold my first engine to a paying customer at age 13... Being a car nut myself it's pretty easy to put myself in the place of the purchaser when prioritizing developments.

The 3.2>>3.6 has been the engine that has gotten the most response thus far, and we weren't expecting that as much because the 3.2 engines are newer and don't fail as frequently.

Hi Guys,

May be a little OT, but have you guys seen the price of the rebuilding at Autofarm.? Okay they are doing the Silsleeve rebuilt cylinder block at the same time, and this is UK pricing, but still all options are 11K (US) plus.

I was under the impression that if you exchanged your core, a 03 996 factory recon engines from someone like Sunset are available for 12K US. Wouldn't most people go this route in the event of a situation like the above?

I simply wouldn't spend more than 4K for a rebuild. Say 3K for parts + 1K for labour. Anyone know how many hours it takes to rebuild a M96 engine to see if my labour is fair?

Might be, since the rod bolts broke as wel as the beam too, but the crown of the piston looks baked, like it was well done under boost :-)

1) We are thinking of getting a junkyard engine put in. Has anyone here bought one and for how much approximately?

2) Should we have them drop it just to confirm the issues since it has to be dropped anyways in case its lesser of a problem.

3) Any other options that im missing here?

Thanks

1) http://www.911pcar.com/index.php?page=pors...es_complete.htm

2) Defer to someone with more experience on that one - not sure what you can check and cannot check with the engine in, but the Bentley manual suggests you can get to the head with the engine in.

3) Ebay - engines start at 5K.

Donate your core + cash for a new or reconditioned engine

Get a new/used 996 3.6l !!!

www.986fix.com if you are feeling handy! He's actually producing a M96 engine service manual

There is a thread on indys doing rebuilds on here also

Well the last 986fix video quotes the costs at just under 3K for his particular repair - cylinder head machine(I think?) and then whatever else he decided to replace. So the 4.5K would just represent a hell of alot of time/expertise, which is probably fair.

Would love to see more options for repairing Boxster engines, but it doesn't seem to be cost effective. The last time I checked a rebuild on a 914 engine cost $7500 for a basic rebuild and much more for performance builds. How much is a replacement from Porsche again, $8000-9000?

No argument with the economics - All I'm saying is there is alot of info in the public domain for people to train with now also.

Or maybe it's because the Boxster has been out over 10 years and there are enough out there to finally make rebuilding (and improving) the engines worthwhile? Not to mention the value of the Dollar relative to the Euro these days. In the UK the Porsche new car warranty is only 2 years, and places like AutoFarm have been doing rebuilds for several years already (see http://www.gormanms.com/docs/boxster_motor_myth.pdf which is referenced in the boxsterspec thread in my original post). My take is that Boxsters (and 996s) are getting older, the resale value on older Boxsters is relatively low compared to the cost of a replacement engine (i.e., less affluent Boxster owners than in the past), so the economics are changing to the point where when the engine grenades, you either essentially walk away (dealers offering $3 or 4K for the dead car), put in a Porsche remanufactured engine, or now go with something possibly a bit more robust. Or do what Mr 986fix did and fix it himself. Over 100,000 Boxsters sold and they're all getting older. Look at all the aftermarket engine part and service suppliers for the air cooled 911 motors out there, now that they're no longer in production Porsche cars.

Could www.986fix.com have anything to do with this sudden injection of confidence? The guy that did it is planning to produce a M96 engine rebuild manual also with workarounds regarding the Porsche hard to source special tools. The vids were very good.

shameless plug!!!!

I have a 2000 3.2 that has a some leakdown issue that will need new rings to be 100%. The motor has 52000 miles and still runs fine but I am adding a 3.6 to my "mod list". I will be selling my 3.2 for 3500USD. PM me if anyone is interested. I will be taking the car on a 300+ mile trip this week with the 3.2 still in it so yes it does still run good.

Btw,

I see there are already a couple available:

http://www.myprojectcars.com/product_info....59e1b11df8d8442

http://www.gmpperformance.com/index.cfm?PG...8&MFGID=284

I still think a low mileage 04 or 05 Turbo would be a good candidate for a nice conversion project if it could be done with the original parts

Cheers,

What sort of $$$ would you be talking? I see some great prices on 04/05 Turbos on Ebay at the moment so this may be quite interesting....

By the way, can you not do a proper Porsche part replacement on the front if you were willing to change the fenders?

Hi, I just want to know when is the Cayenne going to change face? Or change body?

Thanks,

Clifton

For 2008, there is already a facelifted Cayenne which they call the 957. I'm working on a retrofit kit to facelifts a 2003-2005 to this 2008 look. Available in Turbo and non-Turbo flavors. :-)

Any interest fellas?

Sprint.

Hi Guys,

Local Service Centre wasn't to hepful when I asked to borrow their RMS fitting tool!! Anyone know where I can get one of these online, or a suitable alternative to acheive the correct recess.

Hi Guys,

Wow - the favourite RMS has many flavours/fitting techniques it seems :D

So I have a good used 03 996 3.6 motor to install into my 986 - with no leaks. I thought I'd install a new seal now anyway as the engine is out of the car at the moment.

So my first question is do I need the special Porsche tool detailed in the adobe article. I saw this write-up http://www.c-speedracing.com/howto/996rms/rms1.php and they seem to have done a good job but missed the use of the tool for the 5 mm recess.

And what RMS do I get:

- 997 seal

- GT3 Motorsport seal reversed

- 4th generation Cayenne style seal (is this the same as the 997)

Finally can anyone point me towards any guides on IMS replacement procedure?

Quite interesting that the article started off with a link to how reliable the M96 engine wer and ended with this one, basically saying that all the engines will all end up with oval cylinders :o ?

It seems like the author knows his stuff but it seems a bit subjective to me -biased towards fixing on their methods.

If you are forced towards a 15K bill and you have some time on your hands:

http://www.986fix.com/

is about to publish a manual for the home mechanic to rebuild these things! He had a similar problem and when Porsche refused a replacement he went on a bit of a mission.....seriously impressive videos on YouTube!

I like the idea of a full car scissor jack, but it may be out of my price range (shipping/weight is the issue) - this project is already mounting the $$$ up. I was thinking more along the lines of one of the engine scissor benches. Then again until I know how high etc I need to lift the car, something like that may be my only option.

Yup living in Dubai, flying all over MEA for the job...unfortunately not enough time for the car :-(

You know i don't have the issue with me now but in the latest Grassroots Motorsports Mag there is a company that sells a large sissor jack. It slides under your car in the middle and you place the 4 jacking points and away you go. Fast and easy. Might get in the way of an engine swap.

Btw are you flying/working in Dubai?

So the 3.6 is on it's way - roll on 340 HP! It will be a long project however as I want to do it myself based on Todd's guides. But, without AC in my garage, it rules out the summer in Dubai where I am currently! (too hot for another two months)

Anyway I was searching for any internet info on DIY Boxster engine drops without professional hydraulic lifts - I.e Jack stands/Jack/Scissor Lift. Can anyone point me in the right direction if this is an option? I’ve ordered a Bentley book from Amazon, which is on it’s way but it would also be good to see if there is a Howto out there.

I'm not an engineer but I don't like the hockey puck idea on that sill. This thread offers a good solution for jack and strong jack point placement, which will allow wheel removal or oil changes:

http://www.renntech.org/forums/index.php?showtopic=20922

I also put a truck tire underneath like their advice - just a bit bigger!

I am sure that the bending isn't damaging anything important, but if I can jack the car with out hurting anything I would prefer too.

When I started to jack it up ignoring the buckling I heard a loud creaking sound. I immediately lowered the car to discover some bending, that was a little worse than I am comfortable with. Perhaps, the hockey puck I just bought will help.

Well the engine had been ordered and on its way :)

:renntech:

Hey leboneez, how much was your engine/shipping and where from?

Agreed on the air - It's just discussed here by others when I searched.

So the clutch definitely isn't worn out. It was like this from new and now only 17K non raced miles. However if I swapped for saw a sachs sports clutch is it likely to offer a different config re the return height?

Introducing air in a hydraulic system is not a hack but rather a stupidity, in contrary it is a must to have all the air out of the system. The clutch is worn out if the biting point is to high, al you have to do is a clutch replacement.

Fair play, but I still think if I had supercharged may car, inserted a 3.4 and then a 3.6, creating what is essentially the 986 dream car, I'd have been tempted to have a few timed sessions. Excellent info nonetheless

No idea. I value my clutch, tires and trans more than I do having a 0-60 time to brag about online. ;)

:thumbup: This probably rates as the most intelligent comment I've ever read in any online car forum! Todd, I've been extremely impressed with your mechanical knowledge and ability, and here's another side of you to have high regard for :thumbup:

+1 on that! :clapping: