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Old 03-26-2013, 04:19 PM   #1
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2004 Boxster S SE 550 spyder to 3.6

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)











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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust

Last edited by jsceash; 03-26-2013 at 04:22 PM.
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Old 03-26-2013, 05:05 PM   #2
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This is butifule !
Would be great if you will document the process and share it with us.
Good luck.
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Old 03-26-2013, 08:27 PM   #3
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One less '04 SE....

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'04 Boxster S 50 Jahre 550 Spyder Anniversary Special Edition, 851 of 1953, 6-sp, IMS/RMS, GT Metallic silver, cocoa brown leather SOLD to member Broken Linkage.
'08 VW Touareg T-3 wife's car
'13 F150 Super Crew long bed 4x4 w/ Ego Boost
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Old 03-27-2013, 05:52 AM   #4
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Quote:
Originally Posted by Timco View Post
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.
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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust
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Old 03-30-2013, 07:24 PM   #5
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Update

Making progress today



Crank Completed.



Pistons in 1-2-3



First head installed
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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust

Last edited by jsceash; 03-30-2013 at 07:28 PM.
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Old 03-30-2013, 07:33 PM   #6
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Head 4-5-6 assembled



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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust

Last edited by jsceash; 03-30-2013 at 07:36 PM.
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Old 04-13-2013, 05:13 AM   #7
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Update

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.
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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust

Last edited by jsceash; 04-13-2013 at 05:16 AM. Reason: Add pictures
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Old 04-13-2013, 06:31 AM   #8
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I was thinking of buying that car to part out. That looks like a great project.
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LB/GG/MB 02 2.7 sold
MB/GG 02 996TT
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Old 04-14-2013, 04:43 PM   #9
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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.
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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust

Last edited by jsceash; 04-14-2013 at 04:56 PM.
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Old 04-15-2013, 06:28 PM   #10
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What is the expected crank hp from this enlargement?

Thanks,
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2004 50 Years of 550 Spyder Anniversary Edition
(worst name for a car EVAH)
2002 996TT X50 Artic Silver, Natural Grey (which is black)
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Old 04-16-2013, 09:04 AM   #11
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Great thread!
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2002 Boxster S with a few goodies, my 2nd Porsche.
1st was a 1966 912 hand me down from pops
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Old 04-16-2013, 01:06 PM   #12
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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
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00 986 S....with a few tweaks

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Old 04-17-2013, 07:01 PM   #13
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Project complete

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.
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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust

Last edited by jsceash; 04-17-2013 at 07:04 PM.
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Old 04-20-2013, 03:21 PM   #14
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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?
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Old 04-21-2013, 12:25 PM   #15
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Originally Posted by Dr.Strangepork View Post
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.
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2003 Black 986. modified for Advanced level HPDE and open track days.
* 3.6L LN block, 06 heads, Carrillo H rods, IDP with 987 intake, Oil mods, LN IMS. * Spec II Clutch, 3.2L S Spec P-P FW. * D2 shocks, GT3 arms & and links, Spacers front and rear * Weight reduced, No carpet, AC deleted, Remote PS pump, PS pump deleted. Recaro Pole position seats, Brey crouse ext. 5 point harness, NHP sport exhaust
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Old 04-21-2013, 06:47 PM   #16
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Quote:
Originally Posted by jsceash View Post
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
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Old 04-22-2013, 07:03 AM   #17
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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?
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Old 04-22-2013, 10:09 AM   #18
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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!
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Old 04-22-2013, 11:47 AM   #19
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That link has the owners manuals, but the workshop manuals are only for the 986.
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Old 04-27-2013, 07:41 AM   #20
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Originally Posted by jsceash View Post
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
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