3.4 Project Begins!!!! - 986 Forum - The Community for Porsche Boxster & Cayman Owners

JAAY · 01-28-2009, 01:35 PM

Anyone have an oil dipstick, the housing? I forgot that I broke mine when I took the motor out.

Stroked & Blown · 01-28-2009, 03:50 PM

I don't think this is exactly what you're after, but check it out: http://www.pelicanparts.com/catalog/shopcart/986M/POR_986M_ENGoil_pg1.htm#item2
You could always contact pelican or suncoast for the specifics. The Oil Filler tube is only $38, so the dipstick tube couldn't be that much.

JAAY · 01-28-2009, 05:27 PM

yea, not that. I found one on ebay but it is for a newer year and a S. So I don't know if the placement will wind up the same in my trunk. Thanks for looking though, it's pretty cool that you even looked that far for me.

Jay

CJ_Boxster · 01-28-2009, 11:42 PM

interesting. I cannot wait to read ur writeup!

JAAY · 02-03-2009, 03:36 PM

So the project really begins...

Boxster 2.5 on the left Carrera 3.4 on the right

First off let me say these motors are heavy. 450lbs to be exact.

Below is the photo of the front motor mount mounting hole that is talked about in todd's swap. For some reason or another I do not have that on my boxster or the 3.4 motor. I am just pointing it out to show you. This is a photo of the 2.5 motor. The front motor mount is only bolted up with three 15mm bolts.

The 3.4 has the same three bolt locations so there there was no reason for me to concern myself with the extra bolt location. The photo below shows the stock 3.4 mount.

So I removed both mounts the 3.4 and the 2.5. The big difference is that the 3.4 is mounted with studs and the 2.5 is mounted with bolts. These need to be swapped. I just used a vice grip and spun out the studs on the 3.4 and used the 2.5 bolts. They were a perfect fit. The reason for this is the 2.5 mount is thicker than the 3.4 metal. Photo below to show what I mean.

To be continued in a few minutes... Dinner time..

tholyoak · 02-03-2009, 06:02 PM

Actually, all four mounting bolts are present on both engines, it is the cap screw to the right of your finger in the second photo. The old boxster engine mount on your 986 motor simply doesn't have the fourth mounting position. The first update of the mount many years ago was to add the fourth mounting position. I would recommend updating the front mount to the newest mount and use all four mounting points while you have things apart.

Also there are 4 mounting points on the 996 mount. Remove the stud of the one to the upper right in the photo and replace it with the cap screw at the same position on the front of the boxster motor. As you already found out the mounting studs on the 996 motor must be removed and you use the boxster mounting bolts.

It is too late now but you don't need to break open the AC system to remove the motor, just remove the compressor from the motor, that way recharging the system isn't necessary.
Have fun.

-Todd

JAAY · 02-03-2009, 07:25 PM

Thanks for the update about the updated mount.

I had no real method to my madness on the breakdown of this all. So next I started swapping some things from Todd's write up. Here are some photos of some parts that were swapped, and all need new gaskets. 2.5 photos first then the 3.4 photos.

So those two water outlets have to be swapped along with these also.

Here are two more parts that have to be swapped. The first on is the cap that is on the water pipe on the 2.5 motor and then other is the water outlet from the 3.4 These also need new gaskets.

Next I looked at the Oil Pressure Gauge sensor. If you want to keep it all in stock location you have to do some moving and plugging. I did not get to do this yet but I took some shots of what you have to work with. The sensor sits on the opposite side of the motor on the 3.4 than the 2.5 You could use the 3.4 sensor, I am just going to use the 2.5 sensor. If there is any question which is which the 3.4 sensor is the larger gold vdo sensor.

I took a photo of the plug to fill where the old sensor was. These plugs are on both motors just on the opposite sides.

Next I took off the intake manifolds. There is no real magic to this, just becarefull of the different vacuum lines not to break them. After I took them off I removed the oil filler tube from the 3.4 and removed the oil dipstick tube from the 3.4 I did not replace them yet with the 2.5 fittings. I have not taken the other motor apart yet to this point. I don't know if you have to do this but I pulled the alternator pulley and bolt to move it over a tiny bit to get to one of the 10mm bolts holing in the oil filler tube. The oil filler tube and dipstick need new grommets too.