2004 Boxster S SE 550 spyder to 3.6

[jsceash]

Well last fall and early winter I spent several months looking for the right newer Boxster to invest in. Trouble being no one wanted to pay anything as a trade for my 2003 2.7 5-Sp. I spent 2 weekends and put every stock item back onto it and still no trade value. In reality there isn't a thing wrong with the car. So I decided to refresh it. In January I purchased motor from a 2004 Boxster SE 550 spyder. I sent the block to LN and today it returned as a 3.6. (some assembly required)

[Meir]

This is butifule !
Would be great if you will document the process and share it with us.
Good luck.

[Timco]

One less '04 SE....

[jsceash]

Originally Posted by Timco

One less '04 SE....

There was Beautiful silver SE in northern New Jersy victim of Katrina that this motor came from. I picked it up as a working engine it was bad. Electrically the car was unrepairable.

The motor at least is getting a second chance.

[jsceash]

Making progress today



Crank Completed.



Pistons in 1-2-3



First head installed

[jsceash]

Head 4-5-6 assembled

[jsceash]

I was surprised the motor block is exactly the same on the outside. I had the 3.2 and the 2.7 blocks side by side in the garage they measure the same. Size wise the only real differences are the oil cooler and starter, noticeable buy size on the outside



They look the same in the car as well



Project getting close to done.

[Ckrikos]

I was thinking of buying that car to part out. That looks like a great project.

[jsceash]

Buttoned up loose ends today Installed the center radiator and covers. Filled with water and antifreeze but I didn't take as much as expected only 4.8 gallons. new Pentosin PS fluid.





On the first attempt the motor turn over popped a carried on, then shut off. Second attempt ran about 30 second and shut off. The third time was the charm, it kicked over almost immediately and revved right up.

[NoGaBiker]

What is the expected crank hp from this enlargement?

Thanks,

[HAUSIDMT]

Great thread!

[jaykay]

What intake set up will you be using?

Can you tell us if the stock 550 SE intake tract has a helmholtz chamber of any kind?

Pictures would be good but I realize that you must have your hands full

Also very curious to see what the stock air box looks like and how it fits in the engine bay. How is the 987 air box "muffler" chamber accommodated in there???

It may be that this muffler is the helmholtz chamber that we are all shaving off

Oops just realize that you don't have the 550 body

[jsceash]

I'm calling it completed but I do need to build a box around the air filter to keep hot exhaust air from the exhaust and compartment from being pull in the engine. the front bumper was installed today



The air filter is OK but not optimal



The exhaust is loud compared to the 2.7 with the same setup. I was able to log about 20 miles this evening with no issues. low end is not a lot better than my original motor. At about 3500 if you pedal the gas it pulls you hard into the seat.

[Dr.Strangepork]

Wow, nice work, I really wanna have LN do a displacement upgrade for my motor someday

Where did you find instructions on how to reassemble the M96?

[jsceash]

Originally Posted by Dr.Strangepork

Wow, nice work, I really wanna have LN do a displacement upgrade for my motor someday

Where did you find instructions on how to reassemble the M96?

First there is a U-Tube video set that someone with a cracked cylinder made. The problem with that was no real specs or clearances or torqueing specs. I purchased a Porsche manual for the 2005 - 2008 Boxster it was the only manual out there that covered the 3 chain engine. This had all the clearances. It gave all the torque specs for every bolt in the engine. The timing procedures and it shows what tools you can't do without. It was very good for removing and installing the motor and transmission. My suggestion for anyone going to attempt this is view the video. Then buy a comprehensive manual. I've had many years of experience building motors, a good manual is a must.

[Dr.Strangepork]

Originally Posted by jsceash

First there is a U-Tube video set that someone with a cracked cylinder made. The problem with that was no real specs or clearances or torqueing specs. I purchased a Porsche manual for the 2005 - 2008 Boxster it was the only manual out there that covered the 3 chain engine. This had all the clearances. It gave all the torque specs for every bolt in the engine. The timing procedures and it shows what tools you can't do without. It was very good for removing and installing the motor and transmission. My suggestion for anyone going to attempt this is view the video. Then buy a comprehensive manual. I've had many years of experience building motors, a good manual is a must.

Thanks for the info

[stephen wilson]

Last time I checked I couldn't find a manual for the 987. I thought Porsche only had the electronic version they charge a fortune for?

[Bfan]

Originally Posted by stephen wilson

Last time I checked I couldn't find a manual for the 987. I thought Porsche only had the electronic version they charge a fortune for?

Try this link here

Took me a few nights to find it, hope it still works!

[stephen wilson]

That link has the owners manuals, but the workshop manuals are only for the 986.

[Pkvoss]

Originally Posted by jsceash

There was Beautiful silver SE in northern New Jersy victim of Katrina that this motor came from. I picked it up as a working engine it was bad. Electrically the car was unrepairable.

The motor at least is getting a second chance.

is this it?
2004 Porsche Boxster S 2 door Rolling Chassis in Race Cars (Not Street Legal) | eBay Motors