tholyoak

Loren,

are you sure it replaces the pistons. I was under the impression it is just a top end kit.

According to the Tech Bulletin

-new intake manifolds with modified cross-section and made of cast aluminum

new intake pipe supports

new exhaust manifolds with larger cross section and optimized flow

new cylinder heads with optimized CNC milled inlet ports

new camshafts with larger valve stroke on inlet side and modified inlet an outlet timing

new intake valve springs to account for longer stroke

modified partition box in oil pan

new DME maps

additional center rad

That is why you can add it after the fact to a normal 3.6 motor. It will be interesting to compare as the dyno curve shows you loose some low end torque to gain the top end increases.

And don't worry, it is getting a new performance clutch and lightweight flywheel.

Todd

Stefan,

i would appreciate the information, thanks a lot.

Todd

Todd,

I was also interested in getting the amp plugs so I did some research from the manufacturer part numbers for the connectors (not the Porsche part numbers). I found the data sheet and at least one place that sells them. I haven't ordered them yet and I am on the road now so I don't have the information handy. But I can send it to you when I get back home later this week.

Mental? Nope, just like to tinker, especially when people tell you it can't be done.

Eventually we will get to an X51 3.8. The process of physically fitting the motor is really not much different than any of the other engines that have been in there. The limiting factor on these larger motors is getting a proper exhaust to work with the larger displacement motors as the largest of the aftermarket systems for the boxster are designed for the 3.2. With the X51 I am going to try and modify the stock X51 headers to work.

Todd

Well you are probably all getting bored with all the engines my poor car has received. But I couldn't resist a good price on a brand new X-51 3.6 even if my current 3.6 only has ~15k miles on it.

It should be here on Friday.

Todd

Here are some pics of the supercharger when I removed it from my car.

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/DSCF0013.JPG

Todd

Tool Pants,

Richard Hamilton emailed me and pointed out that the 2003 and later wiring diagrams actually have Porsche part numbers for the different connectors in the pictures. Based upon what you say it seems like they can't be ordered though. I'll let you know if I find anything out.

Todd

Toolpants,

Yeah, I've noticed the diagrams as well. I have no idea what the numbers above each figure correspond to. I can locate all of the connectors for the DME on the diagram and their corresponding numbers but I don't know if I gave them to the guy at the dealership whether he would know what I was talking about. The connectors themselves have a Tyco/AMP part number but I can't seem to locate the number on their site.

Todd

Tool Pants,

I used the tool to do all the rewiring for my DME 7.8 integration into my '99 and it worked pretty well. Not the best tool ever made, but certainly works well at a fraction of the cost of the factory tools.

Now on a related question, do you know if the AMP connectors for the DME are available as spare parts?

Todd

I will bring this back to life.

I bought the Sir Tools 9025 - the swiss army knife thing with 12 tools. In the first picture is also the Sir Tools 9701 round pin tool (now discontinued) that I bought years ago, as a reference for the picture. The 9025 has 5 round pin extractors. I have not yet tried to use the 9025. There are different style connectors used by Porsche so I will have to see what style connectors are covered by the 12 extractors. However, the 12th is a joke - just a flat blade screwdriver bit.

There is also a Sir Tools 9024. Same swiss army style but with 6 exactractors. The poor quality picture is from the internet as I do not have this tool. But I can see from the poor quality picture that at least some of the 6 extractors in 9024 are different or look different than 9025

Drop me a personal message or email through the board and I'm sure I can help you get things sorted out. You essentially have two options, 1) integrate all the necessary wiring and systems to get the later DME into your car, or use the same piggyback setup I used prior to integrating the 7.8 DME into my car.

Todd

Finally found some time to work on the car yesterday. I integrated the 2002-on 7.8 DME and egas into my '99 Boxster to run the 3.6. I had been running the 3.4 DME (5.2.2) with a piggyback controler since November but I wanted the factory setup. I still have the early 996 instrument cluster, and didn't update any of the other electronics (yet) beyond the DME (same keys, same immobilizer, same HVAC etc). So it is possible to put the later DME into earlier cars without updating all of the other systems. I did loose cruise control right now, but I will hopefully have that solved when I get some more time.

All systems check out via the PST2, I do have a CAN bus timeout error on the cluster and PSM since the car has neither of those CAN bus systems. I may update to the later instrument cluster if I can pick one up reasonably.

Todd

Hallo Todd

Is it possible to tell me what moifications you made in order to run your boxter with the 7.8 DME.I remind you that I put an 3.6 engine to a Carrera 4 3.4.I am still have problems with the Vario cams.I control the valve lifts with an external circuit but I cannot correctly control the cam timing.With the solenoids of variable timing connected, the car has a constand fluctuation on the RPM's.When I dicconnect them it is kind of slow at low RPM's but it's ok at high RPM's.So now I am thinking of replace the 7.2 DME to a 7.8 in order to have the correct solenoid controls.The only difficulty is that I have to have the engine head dismount in order to change again the ignition cam disk to an 3.6 original one because the one that I use now its converted(cutted) like the 3.4 engine.

So Todd what would you do in my case?If you have any idea how I may do this engine to work correctly I would appreciate it and of course if you are able to sell me any documantation of the convertion it would be fine.Thank you

Without providing a better, more accurate description it will be pretty hard to help you out. What exactly did the fellow do with the scan tool? Was it a PST2? What codes if any were present? Did you address CJ's suggestion and double check that the fuel pump was installed correctly? What lead you to surmise that it was the fuel pump that was bad to begin with?

Todd

Why not simply go to a custom exhaust place. They could bend you up some nice tubing and weld on the correct flanges based upon the shape of the cat pipe you are replacing for a lot less than the $500 Fabspeed charges.

Todd

A 3.4 really isn't going to give you much over the 3.2, especially for the cost. If you are upgrading a base boxster fine, but to spend the money on a 0.2L displacement increase really isn't worth it. A good exhaust system will put you in the same ballpark as a stock 3.4 albeit a bit down on torque, but not much. If your motor is blown and you have the choice of 3.2 vs 3.4 fine, but to upgrade a good 3.2 to a 3.4 doesn't make much sense to me. Just my $0.02

Todd

Did you do the egas throttle adaptation? Turn the car on for 1 minute without touching the gas pedal, you will hear the egas actuate, after 1 minute turn off the car, and remove the key. The throttle is now readapted.

Todd

Tap into the gy/bu/rd or gy/bu/bn wire to any lighted switch. This is the LED dim controlled output from the instrument cluster. If it is a higher draw than that use the gy/bu wire from the cluster to the hvac, the lighter light the ashtray light or the headlight switch.

Todd

I just purchased a brand new one from Jeff at Sunset for $158. It is worthwhile to check the price of new parts from Sunset. I have often been quoted prices on used parts that are higher than new from Jeff.

Todd

Depending on the condition of the rest of the car, I would say $7-8k is what it is worth with a blown motor. At least that is what I would give you for it. You can certainly replace the engine for less than $14k if you use a used motor. You should be able to get a 2.5L motor for about $3k or so. If you want more performance put in a 3.4 engine. If you want to go crazy, put in a 3.6 or 3.8. Costs go up accordingly.

If you are going to sell the car as is, let me know, I might be interested in it depending on the condition of the rest of the car.

Todd

I have always had great experiences with Oklahoma Foreign. It is nice that they are only a days shipping away as well. You might want to give them a call next time around.

Todd

Sounds fishy to me, an early 5.2.2 DME cannot be reprogrammed with the PST to operate a 2000 egas car that ran a 7.2 DME. Are you sure the 1999 DME isn't from an egas C4?

Also if the DME was replaced in the donor car, the programming codes may no longer correspond to the car's VIN. It is easy enough to check the VIN of the car that the DME came from, just go to Vehicle data and look at the VIN present. If it doesn't correspond to the VIN that LA Porsche gave you, try getting the codes for the vin present in the DME. Also many times when a DME is replaced with a new one, people will not enter the old programming code, leaving it the default zeros. They could try that as well.

As Loren states, all the conditions on the PST2, charger on, loads off etc, must be met as the PST2 looks for a minimal voltage signal before allowing programming.

Todd

Just to update, I have all the CAN bus systems integrated and everything seems to be working just fine and the PST2 confirms that. Sort of interesting to have the dot matrix display cluster in a '99 Boxster. Anyway, for those that want to do this you will need 2002- 996 cluster (or 2001- Boxster cluster), the later CAN bus HVAC controller and the later CAN bus ABS controller. In addition if your Boxster is not E-gas you will need the complete egas pedal assembly. This is in addition to the engine and 7.8 DME, and modying an engine harness. Then it is a matter of wiring it all up.

Todd

Richard,

Thank you sooo much.

Todd

Well my PET version is older than yours, so not quite so informative. I think I can find the info though, it will just take a bit. I'll let you know.

Thanks again

Todd

Loren,

Thanks, I had the Boxster ones from you guys already. In the PET catalog when searching order types they all seem to come up with the similar information that is Carrera Cab and only some have a difference in the engine type. Most span M96.02-M96.04. So the PET doesn't seem to be that informative. For example I get the same result searching 996110 as I do 996410. This is why I was looking for the information directly from the people who have the cars.

Perhaps I am doing something wrong I don't know.

Todd

I am trying to populate a list of what the different 996 order types correspond to. Thanks to Richard Hamilton and Loren I have the following:

996110 - C2 USA

996111 - C2 RoW

996120

996121

996210

996211

996310

996311

996410 – C4 USA

996411 - C4 RoW

996430

996431

996440

996441

996610

996611

996630

996631

996810

996811

996850

996851

So if you have a PST2 or a Durametric and can read out the order type in the DME info section I would appreciate the help.

Thanks

Todd

Sorry but that just isn't true. Sounds like they don't know what they are doing. I have programmed several DMEs from 986 to 996.

Todd

The car already has one controlled by a thermostatic switch mounted to the intake manifold. Just splice a switch into the circuit if you want to manually run it. You can also run it manually through the PST2.

Todd