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Posts posted by tholyoak
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Status ???
Not much to report, waiting on a few parts needed for the swap, also been out of town and busy with work, so the actual swap won't probably happen for a couple of weeks
Todd
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In conjunction with the 3.4L engine I am swapping in a 996 gauge cluster. I finally picked up one that will work, turns out to be from a C4 so the gas gauge won't be accurate I guess.
Everything functions fine as far as the gauges are concerned but there seems to be some pin incompatibility between the C4 cluster and the Boxster harness.
With the new cluster the low brake fluid level and the ABS light are illuminated when the car is running. In addition the LCD backlight never goes out even after sitting overnight (long after the actual LCD display goes out).
So I was hoping someone has the pin out diagram from the factory manuals for a early C4. I have the manuals for the Boxster so I would like to compare them and see what I can come up with
Thanks
Todd
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2) as long as you don't have a '97 ECU it is easier to have the ECU reprogrammed, and not have to worry about the driveblock, you will utilize the Boxster DME harness as well not the one on the 996 engine.
When my 2.5 engine eventually explodes I will probably get this done, so:
1. What is the problem with the '97 ECU?
2. What is a driveblock?
Hope the project is going well.
Based upon info on Trent Carter's site (before it disappeared), his '97 DME couldn't be reflashed, he had a DME ending in .02 that no one could reflash so he had to buy a later DME, which obviously increases costs. Not sure if this is still the case but something to look into if you have a '97 with this DME part number.
Driveblock is part of the anti-theft system on the car. I believe it functions by the driveblock and DME are a matched set, if one doesn't recognize the other the car will not run. On 993's this function could be removed when the DME was reflashed, not sure if it can be done on the Boxster/996. Also on the 993 the euro cars didn't have the driveblock issue so you could run a 993 engine in a swapped car with a euro DME and DME harness. I think the driveblock is worldwide on the 996/986 series of cars but I am not sure.
The swap hit the first snag when removing the 996 headers. Even with the heating of the bolts with a torch, 7 of the 12 exhaust manifold bolts broke, so now I will have to weld nuts onto the protruding studs and try and remove the remains of the bolts. Hopefully I won't have to resort to drilling too many of them out. I don't know what Porsche was thinking with steel bolts, threaded into aluminum heads, high heat and no anti-seize and obviously these have never been out since the engine was put together.
Todd
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I can't wait to see!! I am drooling just thinking about it! What is the power in the 3.4?
Jeff
Jeff
People quote around 320-340 hp at the crank depending on the DME reflash and header/cat system. I think stock Porsche numbers are 300hp.
Todd
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A number of people have done this. If you have not, you should ask around for info. If memory serves me correctly:
1) you will have to fabricate engine mounts (the 996 motor is an inch taller (maybe shorter) and it must be dropped another inch to fit the boxster.
2) You have to change or flash the ecu
3) I am assuming you got a 3.4 motor. A 3.6 needs egas which your 99 does not have.
4) There are some issues routing either the fuel lines or the AC lines. Also I think one of these was not long enough and had to be changed.
5) There were some issues with the fuel rails and throttle body sizes. Details escape me.
6) You did not say what tranny you are using. If the original 5 speed you might want to put in a better clutch.
Good luck.
1) you don't need to fabricate mounts, you use a combination of 964 C2 motor mounts at the rear and 3/4" spacers at the front.
2) as long as you don't have a '97 ECU it is easier to have the ECU reprogrammed, and not have to worry about the driveblock, you will utilize the Boxster DME harness as well not the one on the 996 engine.
3) as the subject title says it is a 3.4
5) I am getting around the issue of the fuel line connections being in the wrong location on the 996 fuel rails for the stock lines not by lengthening the stock lines but by swapping the 996 injectors onto the Boxster rails. This way you keep the stock lines and the parts are interchangeable, same FPR and all.
6) using the stock trans, it will hold up fine to the power with a new sachs performance clutch.
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Pilot2519j
The work to install the motor will hopefully begin (and finish) this weekend so I cannot comment on the swap as of yet.
Todd
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Steve
Not a new engine, has 20k on it, purchased off of a fellow on the Pelican Parts BB.
I will eventually do a write-up on the procedure when I am finished. I'm hoping it won't be any more involved than the 3.6 swaps I've don into earlier 911s or the 968 engine I put in a 944S.
The car is my daily driver and I can't afford to have it tied up for too long during the process.
Todd
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Yes I will be doing it myself. I will try and remember to take lots of photos during the procedure
Todd
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Tool Pants
Thanks for the reply. Looks like I will have to pick up a 99-01 C2 cluster and sell the turbo cluster.
Thanks
Todd
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So I purchased a set of 996 gauges to install in the boxster. Upon removing the old gauge cluster and comparing to the new one, it appears I have a couple of issues.
1The connectors on the harness don't appear to match the connectors on the 996 gauge cluster. I believe the cluster is from a 2002 Turbo. I understand that the oil level function won't work with this cluster but that really isn't a concern of mine. Do I need to replace the connectors on the harness (the car is a '99 986) or am I simply missing something here?
2)Also the colours of the connectors are different between the harness and the gauge cluster. While they both have a blue connector the other 2 don't match up so I am unsure which connector would go where. I have the 986 workshop manuals but not the 996 so I can't compare the pinouts between the two. Any help would be appreciated. I would really like to use this cluster if at all possible.
3) If I am able to use this cluster, does anyone have the part nuber for the connector pin that needs to be added for the oil pressure gauge signal.
I have pictures of the backs of the 2 clusters I will post tonight if that will help clarify what I am talking about.
Thanks
Todd
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Thanks for the reply, do you have the part number for the retrofit kit.
Thanks
Todd
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They are Mille Miglia turbo twist replicas. Offset is for pre '87 944s and pre '90 911. If you are interested in selling them I might be interested in them
Todd
Need Pin Out Diagram for my Cluster Swap
in 986 Series (Boxster, Boxster S)
Posted
Loren,
Thanks for the PM. After comparing the pinouts it doesn't appear that it is a pinout compatiblity problem. It would appear that the cluster in not compatible eventhough the pinouts are the same as are the plugs. Perhaps it is what you suggest, the difference with egas etc. Perhaps it has something to do with the traction control integrated into the ABS on the C4.All the gauges function correctly, with the exception of the fuel level gauge being incorrect just the ABS and low brake fluid idiot lights are lit. Oh well, now I have 2 996 clusters that I can't use (the first one I picked up was a later year with the different connector plugs).
Todd