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YOUR RESEARCHDrilling into M96 head
Leading reported evidence
Run into my first issue
Performed · outcome unconfirmed
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Leading evidence: 'Run into my first issue' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Run into my first issue' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Performed · outcome unconfirmed · Original poster
I also discovered, the boxter engine used a different mount for the intake riser.
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Suggestion
Involves rewiring the engine to DME, also the instrument cluster, HVAC have to changed and rewired to use the CAN BUS ect.
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Suggestion
I would probably use a hand drill for better control.
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Suggestion
If you got a smoking deal on the 05 3.2, I would sell the 05 3.2 and use the money/profit to buy another 3.4 99-2001 or if your low on funds, buy a 2000-2002 3.2 or any 2002 and older 2.7 2.5 they all will work with Motronic 5.2.2 and be "plug and play", except, With any Boxster engine you will have to drill and tap the holes for 996 muffler brackets.
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Suggestion
If you got a smoking deal on the 05 3.2, I would sell the 05 3.2 and use the money/profit to buy another 3.4 99-2001 or if your low on funds, buy a 2000-2002 3.2 or any 2002 and older 2.7 2.5 they all will work with Motronic 5.2.2 and be "plug and play", except, With any Boxster engine you will have to drill and tap the holes for 996 muffler brackets.
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So my 99 996 engine dechuncked. I am swiping in a 05 3.2 boxer engine mainly because I got a great deal on a RND rebuilt clearance sale. Ran into my first issue. The boxer head does not have mounting bolts for the exhaust mounting bracket that sit on top of the head. There are the castings on the head, but no mounting holes. I have two options as I see it.
1. drill the holes and tap
2. weld the bracket onto the head
to accomplish 1, I was thinking about using my table top drill press and going for it, but this scares the crap out of me. welding may prove to be the safe option...
Just wonder what other folks think about drilling into this head. thanks -- rr
I believe that the castings for the heads are asicallythe same, comparethem visually with your old engine and the new one. If you carefully drill and tap holes you should be ok. But this is the least of your worries. The engine in a 99 is a Vario Cam engine with a 5.2 DME and related equipment. An 05 engine is a Vario Cam Plus engine, totally different DME, valve advance system, no return fuel system, Canbus electrics, instrumentation, the list goes on and on. This is a very complex conversion, it can hand has been done but you may spend more on the conversion than you saved on the engine.
if you are interested I have some training manuals that provide information on the Vario Cam and Vario Cam Plus system that we help explain how different they are.
in any case,good luck with your project.
Just drill and tap the holes. I have done it on several other kinds of engines. Measure the hole depth and tape the drill bit so u dont go too deep. Get a starting and bottom tap so u can get the threads to the bottom. I would probably use a hand drill for better control.
^^This^^... welding dissimilar metals is tough... Swapping a vario-cam plus engine into a vario-cam system (wiring harnesses, modules etc.) is tough and expensive...
Take it to a machine shop and have them drill and tap the bosses. It is unlikely to be expensive, and you�ll know it was done correctly. I�m sure you could drill and tap yourself, but the odds of getting the hole perfectly oriented/aligned with a hand drill or home shop quality drill press seems awfully low.
Oh, and to pile on, there is no way to weld the steel bracket to the aluminum head. Just do it right and tap the bosses.
Since these are only for the muffler brackets, don't waste your time and money by taking it to a machine shop. Do what others said and replicate what the original head has.
^ this ^
Make sure you are 100% sure you can get this newer motor to work in your car before you start modding. If you can't you'll find you will need to sell the motor and folks will want it stock
Like Doug said, mounting muffler brackets is the LEAST of your problems.
Converting a Motronic 5.2.2 car to use a Motronic 7.8 system is a VERY COMPLEX task. Involves rewiring the engine to DME, also the instrument cluster, HVAC have to changed and rewired to use the CAN BUS ect. To me it is not worth it unless you were upgrading to a 997s engine ect..
If you got a smoking deal on the 05 3.2, I would sell the 05 3.2 and use the money/profit to buy another 3.4 99-2001 or if your low on funds, buy a 2000-2002 3.2 or any 2002 and older 2.7 2.5 they all will work with Motronic 5.2.2 and be "plug and play", except, With any Boxster engine you will have to drill and tap the holes for 996 muffler brackets.
Ok a bit of follow up. I did drill into the heads. Since the heads were on a finished engine, I could not bring the heads to a machine shop. I made a gig for my bench top drill press. It fit. I was able to square everything up and successfully drill the holes. Aluminum is so much nicer than cast iron. I also discovered, the boxter engine used a different mount for the intake riser. I could not get my drill press in there at all. So I had to do those by hand. I used the old gasket as a guide, and I was off by fraction of mm's I was able to get things to bolt up, but I will admit, not as good as a milling machine.
Bottom line is a center punch, a pilot hole then a final drill bit worked well.
