Accusump install

[AZ986S]

OK so I just got back from the shop.

It looks like the factory re-manufactured 3.2 engine that was pulled from the donor 2000 Boxster S had the M97 bottom end with larger IMS single row bearing but still has the original Variocam. The fuel rails had the integrated pressure regulator and so had to be swapped with the ones on the pulled engine since the 2002 Boxster S has the regulator on the fuel pump. They also swapped the injectors since they were blue instead of white (what's the difference?).

I have not looked a the intake, but apparently the M97 3.2 makes 280 HP with a larger airbox, larger exhaust and intake. So hopefully the 7.2 DME will drive this engine correctly.

I did read from the Pelican article on Boxster engine swaps that the M97 3.2 (not reman) requires the use of the 7.8 DME, wiring and DME pin changes. That appears to not be the case here with my swap so far. So that is probably what you are referring to Woody for your customer having a hard time with his swap...

More to come...

[JFP in PA]

Originally Posted by AZ986S

OK so I just got back from the shop.

It looks like the factory re-manufactured 3.2 engine that was pulled from the donor 2000 Boxster S had the M97 bottom end with larger IMS single row bearing but still has the original Variocam. The fuel rails had the integrated pressure regulator and so had to be swapped with the ones on the pulled engine since the 2002 Boxster S has the regulator on the fuel pump. They also swapped the injectors since they were blue instead of white (what's the difference?).

I have not looked a the intake, but apparently the M97 3.2 makes 280 HP with a larger airbox, larger exhaust and intake. So hopefully the 7.2 DME will drive this engine correctly.

I did read from the Pelican article on Boxster engine swaps that the M97 3.2 (not reman) requires the use of the 7.8 DME, wiring and DME pin changes. That appears to not be the case here with my swap so far. So that is probably what you are referring to Woody for your customer having a hard time with his swap...

More to come...

Check the engine number on the sump rail; willing to be it has an "AT" in it, but the numbers will tell you what year it was designed for.

[AZ986S]

Update on the engine failure.

I got the car back yesterday
The new (used) engine is running perfectly.
Oil pressure is as you would expect, and the most important is that it is back to normal values.

I set up the pulled engine on a stand today and the first thing I did was pull both scavenge pumps to see if they turn without effort or binding, and if there is any obvious damage. The reason for this is that valve keeper-like debris and other unidentified debris showed up in the bottom of my engine oil sump.

Bank 1: pump seemed to rotate by hand with little effort, but it would bind slightly every turn. That is not good to me. Should it not be a smooth rotation?

Bank 2: this is the suspect bank. When I pulled the pump, it will not turn by hand at all. I did not try to use a tool, but, obviously it turns otherwise the drive key would have sheared off. Then I looked inside the inlet side, and you can see damage from debris being ingested.

Here's a photo of that:



I plan on doing a leakdown test first and will pull the valve covers and inspect.

Best case: top end (head) rebuild?

Worst case: complete rebuild

As mentioned in earlier posts, the engine ran fine with no noises. The only issue I was chasing was low oil pressure at idle. Obviously, this was a ticking time bomb and I caught it in time to minimize damage.

I've done some work on engines, but never have touched an M96 (rebuild).

[AZ986S]

Originally Posted by JFP in PA

Check the engine number on the sump rail; willing to be it has an "AT" in it, but the numbers will tell you what year it was designed for.

I looked this evening and could not find any markings around the sump. Where are the numbers located? Not on the sump plate itself I hope?

[JFP in PA]

Originally Posted by AZ986S

I looked this evening and could not find any markings around the sump. Where are the numbers located? Not on the sump plate itself I hope?

[AZ986S]

OK found it.
New engine is M96/21AT67Y65274
Looks like it was a reman engine M96 version 2.1 model year 2006.

[AZ986S]

Update...

I ran at Wild Horse Pass last weekend and the new engine performed flawlessly. Seat of the pants feels like more power than the old engine since it is a 2006 rebuild. I recorded some in cab video and was reviewing to see how often the accusump came on. In general, right turns will activate the accusump more than left turns. It never activated for more than maybe 1 or 2 seconds at a time. I had my passenger look at oil pressure and temperature (ambient air temp was 95F), and pressure never came much lower than 40 psi, temp never higher than 225F. I am using Mobil 1 5W50 oil. Oil capacity now is almost 11 quarts, so that probably helps in keeping oil temps down.

So I am very satisfied with the results. The next thing I would do is add a pressure sender to the air side of the accusump and a switch on my panel to use the existing oil pressure gauge to read the air preload pressure. This had been suggested by StevedOx.

[michaelpetersen3]

This is a great write up!

Im considering an Accusump for my 01S that sees a lot of track duty. Wonderful build with the Accusump in the tunnel and the switch on the pressure gauge for oil/Accusump.

One question, I have a journal bearing on my IMS (L&N IMS Solution). There is an adaptor plate on the oil filter joint to feed the IMS bearing. I would assume that I can add the Accusump pick up plate to the IMS adaptor plate. Its a little bit of a Rube Goldburg design, but it should work. Or, can I tap into the Accupump plate for an additional small oil pickup to feed the bearing? Has anyone tried this?

Great thread overall, thx for the morning entertainment.