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 Porsche Boxster S 986 - Audi 2.7 Bi-Turbo engine swap View next topic
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 182


PostPosted: Tue Oct 06, 2015 10:34 pm  Reply with quoteBack to top

I thought i'd start a project thread. I recently bought a Porsche Boxster S with the intention to swap the engine for an Audi 2.7 bi-turbo engine.

My plan is for it to look pretty much standard. I'm sure that'll be harder than it sounds when it comes to things like intercooler/charge cooler rad placement and wiring integration.

Here are a couple of photos of the Porsche I took on the way home from picking it up. It's really nice, I haven't driven one before, was quite impressed to the point where I reconsidered my plans. I'd already bought my donor Audi A6  I like the challenge so i'm going to plow ahead.




I spotted my donor car on ebay, an Audi A6 in manual flavour. The miles were pretty reasonable at 106k (the Boxster is on 93k). It'd been sat for a couple of years and I bought it unseen and just hoped for the best. Even though it's covered in filth and full of cobwebs you can tell it's a good car. It's only had one owner since 2001. The engine runs great and is whisper quiet. Check out the front wing, some impressive rust. It came with a free old man hat on the parcel shelf, happy days.



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Human Joist
knowledgeable



Joined: 12 Aug 2014
Posts: 493


PostPosted: Tue Oct 06, 2015 10:46 pm Reply with quoteBack to top

Be a good set up when done mate.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 182


PostPosted: Tue Oct 06, 2015 10:48 pm Reply with quoteBack to top

I've not really made a start on it yet, have been too busy doing other projects. I'm going to start stripping the A6 soon.

I decided to buy a 2.4 v6 to use it's large port cylinder heads. Currenty stripping the engine down, I have some S4 valves so I can build up the heads and leave them in the garage until i'm ready to fit them. I won't mess about with things like this until I know the V6 is going to fit the Porsche.



Last edited by Escy on Tue Oct 06, 2015 10:59 pm; edited 1 time in total
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ScottR
Veteran


Car: B5 S4

Joined: 22 Apr 2008
Posts: 8376


PostPosted: Tue Oct 06, 2015 10:56 pm Reply with quoteBack to top

Cool, always enjoy a wacky project!
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RS666
knowledgeable


Car: S4 B5
Power: 300bhp est
Torque: 360?
Engine code: agb

Joined: 01 Nov 2009
Posts: 392

Location: Leeds

PostPosted: Wed Oct 07, 2015 12:17 am Reply with quoteBack to top

WOW I keep dreaming bout doing this but with a Subaru Impreza STI engine!

Watching with interest  
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Lewis
Skilled


Car: Audi B5 RS4
Power: 576
Torque: 786
Engine code: AZR

Joined: 16 Oct 2011
Posts: 1019

Location: Aberdeen

PostPosted: Wed Oct 07, 2015 2:00 am Reply with quoteBack to top

Nice hat.

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RS4 B5 Ibis white 576hp, 786TQ.
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marc1
Experienced


Car: B5 RS4

Joined: 03 Jan 2010
Posts: 3345


PostPosted: Wed Oct 07, 2015 7:21 am Reply with quoteBack to top

Wow, this will be an awesome project.  The Boxster is a fantastic drive, very direct, light and amazing steering feel.  I think they go pretty well in stock form, so should be fairly ballistic with a tuned 2.7tt.  'Hats off' to you for attempting this.
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Paul
Knows a Bit


Car: A4 1.8T quattro

Joined: 03 Jun 2008
Posts: 247

Location: Edinburgh

PostPosted: Wed Oct 07, 2015 9:39 am Reply with quoteBack to top

Cool project.

Hat may come in useful for sunny days in the Boxster.

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A4 1.8T quattro & M3
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Lewis
Skilled


Car: Audi B5 RS4
Power: 576
Torque: 786
Engine code: AZR

Joined: 16 Oct 2011
Posts: 1019

Location: Aberdeen

PostPosted: Wed Oct 07, 2015 12:43 pm Reply with quoteBack to top

I had a 986 boxster S around 10 years back it really was a great handling car and very manageable on the limit, however I felt it was under powered at times so I traded in for a 996 turbo which was totally different much faster but lacked the go kart feel of the boxster, the chassis and engine combination you have here will be very well matched indeed good luck with the build and be prepared for sore backs and bleeding knuckles as the boxster engine is a pan in the ass to access.  

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RS4 B5 Ibis white 576hp, 786TQ.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 182


PostPosted: Wed Oct 07, 2015 8:29 pm Reply with quoteBack to top

I hope it will be well matched, from driving the Boxster I think the chassis is capable of handling a lot more power, it feels very composed.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 182


PostPosted: Fri Jan 15, 2016 8:13 pm Reply with quoteBack to top

Time for an update, it's been months. I took what was needed from the A6 and got it collected for parts. I barely stripped it, there wasn't much interest which I thought strange.


My aspirations for the engine spec are ever increasing. I would probably be perfectly happy with a tuned K03 set-up but if i'm going to the hassle of fitting this engine in the Boxster I may as well make the most of it. The plan is 500bhp+ now, either on RS6 turbo's or a big single, haven't decided yet.

I picked up a 2.4 n/a engine to use it's big port cylinder heads. I stripped them off and it's all in nice and clean inside, was told it'd done 70k and it looks it.  


I offered up the Audi V6 spacer plate to the original Boxster S transaxle. (in the picture)The starter location was in the wrong place, some bolt hole lined up, some didn't, it also didn't have the flywheel sensor mounting. It was probably workable but lots to overcome and if it can't take the power and blows up i'd have to do all modifications again. The easy way would be to use a 5 speed 986 transaxle, it's an Audi unit so everything would fit fine. Putting a weaker 5 speed in felt like a downgrade so I decided to purchase a later Boxster 987 3.2 transaxle and associated parts. This will provide a few headaches later on.


The car was running out of an MOT and I didn't want to complete a project like this without one. Once I sorted that out, I was ready to pull out the original engine, this was done around the Christmas period. This is a photo of me getting the engine out, lifting the car up with an engine hoist isn't exactly how it's described in the workshop manual!


With that out of the way, i've offered up the 2.7. It fits lovely inside the engine bay. The turbo's foul but i've got stainless manifolds i'll be modifying. The driveshafts are further forward and are causing me clearance issues so i'll be modifying the alloy suspension carriers to rectify that. Here are a few pictures of it sitting in the bay. Need to sort out the driveshafts and I can start making up my engine and transaxle mounts. I'll be running the inlet manifold backwards and will need to modify the throttle body angle as it'll foul the engine cover

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terracota
knowledgeable


Car: s4 b5 Wagon
Power: Mrc Tuning
Torque: K03 TTU400

Joined: 13 Jul 2014
Posts: 294


PostPosted: Fri Jan 15, 2016 8:25 pm Reply with quoteBack to top

haha 2.7tt in ass:P
cool project mate
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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 12087

Location: In front of you, lol'ing

PostPosted: Fri Jan 15, 2016 11:34 pm Reply with quoteBack to top

Serious commitment to a project Tom

Great work so far, I'm sure like me, plenty will be watching this thread

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PM me if you have a S4 FS, always looking for projects.
2002 B5 RS4 Noggy
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
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Challice
Experienced


Car: S4 V8
Power: 340bhp
Torque: 301lbft

Joined: 05 Mar 2011
Posts: 3020

Location: Wiltshire

PostPosted: Sat Jan 16, 2016 10:41 am Reply with quoteBack to top

Looking good
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n33yo84
Brand New, Welcome :)


Car: S2, S6, RS4, RS6

Joined: 05 Jan 2016
Posts: 34


PostPosted: Sat Jan 16, 2016 3:02 pm Reply with quoteBack to top

2.7T + porsche perfect match  

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You can't treat a car like a human being; a car needs love.  – Walter Röhrl
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