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Originally Posted by insite
well, i finally found the right combination of time & money; i finally started the swap. i will document the process, but i am not going photo by photo & taking my time. i plan to do this in a couple of bursts, & i should be complete late this month / early next month.
i will take some occasional photos of the process, and i plan to specifically document a couple of things:
1. stuff i buy. i will keep a running tally of everything i buy along w/ price & source.
2. fuel rail setup. i will thoroughly document however i do this.
3. maf housing / intake setup
4. motor mounting (i.e. how i lowered the motor)
5. LN IMS retrofit
the plan is to install a stock 3.4L motor that i sourced from a guy in NYC. it's a '99, with around 40k miles on it. i will be upgrading the IMS. it looks like EVO Motorsports will build my intake plumbing, with a 996 diameter MAF housing to boot. (QUESTION: do i need a 996 MAF, or am i good with the OEM 986?)
hopefully, todd will reprogram my ECY & supply me with a DME pin for the VarioRam functionality.
i will also be adding a 996 guage cluster w/ analog oil pressure output.
if anyone has SPECIFIC stuff they want to see photos of, let me know & i'll try to accomodate (time permitting).
looking forward to this! my poor car has been sitting for 18mos.
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Your IMS is likely a double row, but there's no way to know for sure until you either match the serial number of the engine and/or visually verify. If you have the motor in front of you, it's pretty easy to tell as the single row has a deeply set flange, while the double row does not. There are plenty of pictures floating around of both types, as well as on LN's site.
Since you will be flashing the DME over to a 996 3.4 program, you will need a 996 size MAF. I am running a Cayman S MAF on my 3.6 based 3.8, which as far as I know is the same size as the 996 MAF and has the airflow smoothing grid. For intake plumbing, I am running a BMC CDA airbox, which gets air through some SCAT hose routed up to the driver side vent, and from the CDA goes through 3 1/2" hard pipe (sourced from Vibrant) and silicone joiners (Hose Techniques) and a silicone elbow (Samco). For my 996 3.6 throttle body, I actually needed a 3 1/4" silicone elbow to get a good fit on the throttle body, which is a very unusual size and was difficult to get from Samco, and then I also needed a piece of 3 1/4" tubing (only place I could find it was Burns Stainless) to make a joiner out of to mate to a 3 1/2 to 3 1/4 silicone reducer as the Cayman S MAF is sized for 3 1/2 pipe. I have extras of all this stuff if you can use it. See attached pic for my setup.
I believe you only have to run the wires from the DME harness to the VarioRam solenoid to make that work.
If you use the stock plastic 996 manifolds, you will need to lower the engine. Seems most people machine spacers for the front and use 964 mounts at the rear. If you get the metal X51 manifolds (you'd need both uppers and lowers, and it uses the same crossover pipes and throttle body), you can actually leave the engine at stock Boxster height.
My donor car was an 03S, so it already had the non-return fuel system, so I merely ran Aeroquip hose to the 996 fuel rails, and re-used the factory Boxster fuel connection to connect to the hard pipe on the car. If you have return type fuel system, I think you're going to have to keep it that way.