Porsche Boxster 986 - engine swap project

Porsche Boxster 986 - engine swap project

Author
Discussion

Dr G

15,207 posts

243 months

Monday 22nd August 2016
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Great work!

Leak or detritus in the exhaust/plumbing?

55palfers

5,915 posts

165 months

Monday 22nd August 2016
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It lives!

Escy

Original Poster:

3,946 posts

150 months

Monday 22nd August 2016
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It's a combination of excess fuel and condensation. It was running so rich I couldn't get it re-started after I switched it off.

Edited by Escy on Monday 22 August 23:12

Wkotuning

44 posts

156 months

Monday 22nd August 2016
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Wow, just wow.

This build is a fantastic, but by far the most impressive aspect... is your ability to keep a missus. laugh

Mine would have bailed quicker than Kate Winslet at the end of Titanic.

Keep the build going strong!

marting

668 posts

175 months

Monday 22nd August 2016
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Top quality work, I would love to have an ounce of your talent! I'd like to see you and mwstewart in some sort of ultimate car build dream team.

Ug_lee

2,223 posts

212 months

Tuesday 23rd August 2016
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Very nice work OP!

I'm always interested in engine swaps especially the integration of the electrics/keeping the ECU happy as that I believe is a bigger part to modern swaps than the mechanical fitting of the engine.

Was both the Audi and Porsche CAN? Will the gauges/dash lights etc work with information from an Audi ECU?

I've got a few ideas for a mad swap of my own with an Audi engine and never considered a Boxster as a base car

Escy

Original Poster:

3,946 posts

150 months

Tuesday 23rd August 2016
quotequote all
Thanks for the positive comments.

I'm lucky the wife puts up with me. smile

Both the Boxster and Audi are pre canbus, they are both 2000 model years. That was part of the reasoning for using the cars I did, wanted to try and keep it relatively simple.

Getting the dash to function correctly will take some time, the rev counter isn't working, the fuel gauge might not work correctly as it seems like the last 1/4 of the tank is calculated by the Porsche ecu rather than from the sender in the tank, the oil level gauge doesn't work, some of the warning lights don't match. Plenty still to be done.

Edited by Escy on Tuesday 23 August 09:01

Ron_Éire

4 posts

97 months

Tuesday 23rd August 2016
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You might hurry on would you....I'm really enjoying this winkbiggrin

lukeyman

1,014 posts

136 months

Wednesday 24th August 2016
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Nice tiles!

I still remember my excitement when I got the Zetec running in my MK4 Escort!

This is a great project. Puts me being foxed by a connector not being pushed together properly to shame. smile


eliot

11,449 posts

255 months

Thursday 25th August 2016
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Did you check the oil after hydro-locking it with fuel? If the fuel gets into the oil, it thins it out and then wrecks your bearings.

Escy

Original Poster:

3,946 posts

150 months

Thursday 25th August 2016
quotequote all
Thanks, I was aware of that so as soon as it happened I took the plugs out, soaked up what I could then turned it over to empty the cylinder. It's surprising far the fuel went, made a right mess. I'll be changing the oil again soon, once I've bed in the big end bearings.

SturdyHSV

10,110 posts

168 months

Thursday 25th August 2016
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Another first time reader here, start to finish, love it thumbup

Don't like Boxsters, saw the title in Readers Cars and thought, you know what, I'm curious.

Glad I clicked on it, and glad it's on the front page of PH as otherwise I wouldn't have found it in readers cars hehe

Keep at it that man, there's only been 2 weeks of summer so far, there'll be more to come soon thumbup

piers1

826 posts

195 months

Saturday 27th August 2016
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Excellent to see it running, a fantastic achievement, roll of the "final" titivation!!

drewbagz

183 posts

165 months

Monday 29th August 2016
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Great build and thread buddy, keep up the hard work. Look forward to seeing this out on the road

Vitorio

4,296 posts

144 months

Monday 29th August 2016
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It's alive!

Should be properly fun when its all sorted and on the road

Escy

Original Poster:

3,946 posts

150 months

Sunday 4th September 2016
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I've spent some more time fighting the drive-by-wire fault codes. I noticed the Audi TT uses a similar pedal sensor to the Porsche so I thought i'd try one as it also runs a Bosch ME7 ECU so there is a good chance it could work. Porsche on the left, Audi on the right.



It didn't work so I decided to get an original Audi A6 pedal, that didn't work either.



At this point, i'm stuck, the pedal sensor values are perfect, the wiring is fine, VCDS reads it no problem. Possibly a hardware fault on the ECU (i'll try it on my mates car since the immobiliser has been removed)

Although it's running i've decided i'm going to take a couple of steps back and go for standalone engine management instead of waste more time and money on this. I originally wanted to keep the Audi ECU as I thought it would be the simpler option, I had hoped that the integration into the Porsche dashboard would have been seamless since they are both on Bosch systems and built in the same year, that was naive, nothing works on the Porsche dash.

Cost was another factor in keeping the Audi ECU but since I spent £400 on a wideband datalogger, needed a separate fan controller, and other bits and pieces it was a bit of a false economy. Mapping will be easier on a standalone and I won't have to rely on my mate to do all the coding on the Audi ECU (it's a lot of work as i've changed so much around). I've wasted a load of time pissing about with the Audi ecu which is a shame but you live and learn.

I don't suppose a standalone will be plain sailing either. I need to make a decision if I try drive-by-wire throttle again or go cable.

Here is my Zeitronix datalogger installed. That's now been removed as I won't need it anymore as the ECU's i'm looking at run widebands.



Escy

Original Poster:

3,946 posts

150 months

Sunday 4th September 2016
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I went to see my friend who's got an Audi S4 and took my ECU, throttle body and pedal with me so I could try them on his car to work out what's causing my DBW problems. Turns out it's the ECU which is what I thought initially.


dom9

8,091 posts

210 months

Monday 5th September 2016
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Did you steal his ECU to try in your car?

Could that be a 'simple fix' instead of having to go full 3rd party?

Escy

Original Poster:

3,946 posts

150 months

Monday 5th September 2016
quotequote all
His has got an immobiliser so it wouldn't run my engine. Wouldn't want to mess about with it and risk damaging it now I've decided to go standalone anyway.

Nano2nd

3,426 posts

257 months

Friday 9th September 2016
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Great thread Tom, looking forward to seeing it at the office wink