After searching for kits for Cayman swaps I decided to make my own using a 2.7tt engine from a 2003 Audi Allroad. This swap will replace the very unreliable 3.4 liter Porsche engine in my Cayman soon to be given to my son.
Carnage from spun rod bearing, seems pretty coming in these other than bore score. So I had all the issues, bore scoring was bad, rod bearing was gone which took the crank and crank carrier along with the driver side cylinder half.
The doner car will be Speed yellow but now is still wrapped in green.
2008 Cayman S
The important things first I had to upgrade the stereo to my teenagers liking. We install a Kenwood strero powered with the OEM Bose amps and speakers.
Next on the list is getting the donor motor, I found one local for $650, looks to be ok but not bad for a mock up engine and or just test fit for the kit.
Yes, I got out in the rain it was a miserable day to be at a junk yard for sure.
I was pretty happy since the motor actually spun over by hand and was not locked up, the plugs look good and the little K03's look ok too, testing the Porsche 6speed transmission to the new engine. So far so good.
I am planning on having an install kit made with instructions, I just need to work out all the details first. The plan to get this running is March 2024, then I will work on how to market the kits.
Stay tuned......
Got the car ready for paint. Sending to painter to get it back speed yellow. The fenders, lights and bumper are 987.2 spec so it should look a little better. Also installing a rear wing side skirts and a front splitter. Hopefully it will turn out good.
4-15-24
Car is one color now. Time to put her back together and get with the engine swap!
Time to start putting the Cayman back together. The painter is done and will pick after the windshield guy installs the new windshield.
My advice is do not buy a car that someone has worked on. The previous owner did some tinkering with the car but it seems everything that was touched has either missing bolts, not tight or broken. The process of fixing the previous neglected items are slowing my progress and motivation down.
After the first attempt to test fit the engine which was not as successful as anticipated.
Good news, did some more test fitting and figured out what was needed. I had to remove two tabs on the engine cover area.
This removal enabled the engine to move up enough to get the transmission mounted properly with our having to move the OEM forward location.
The transmission is about 1.5" lower which is a bummer but the sway bar still clears. Will report once in place. I made a prototype drawing to replace the OEM transmission mounts and engine cradle.
The plan was to keep the stock twin turbos on the S4 b5 engine. After removing them as it was a PITA, I decided a single might be better. Once the cradle is made I will see where to put the single and make sure it is possible.
I found a small clearance issue with the passenger side valve cover. It was very close to the Porsche coolant tank. It did clear but I was worried that if the motor moved any it could damage the coolant tank. So I removed the valve cover and removed the bung that was close.
Made a test trans mount. It worked out better than expected from my hodge podge card board cut out.
Looking at the intake manifold I believe I will have move space for the throttle body if it points to the rear of the car. So I reversed it to test out.
After thinking about the engine mounting method of Porsche I might redo the cradle I have designed up. My fear is that the rear transmission mounts really do not hold the engine/transmission from moving forward or backward, they just basically hold the weight. Maybe over thinking it but will need to do some homework on this. I will be using the OEM Audi motor mounts on the sides of the engine which will hold the engine but need to confirm that the engine will not move forward. Maybe I can use the OEM Porsche front mount and tie it in to the front lower OEM Audi engine mount. This will still be isolated as the OEM Porsche was. Just thinking about it now.
12/1/2024
Baby steps. I made the base of the motor mount cradle. Two sides that replace the OEM aluminum braces and also made a bracket to replace the front motor mount.
Now I need to finish up the transmission mounts and get the motor back in position to get the rest of it.
12/4
Still making some parts for all the mounts. Going smoothly so far.
Made some transmission brackets and mounter mount brackets. Amazingly enough what I had in my head is actually fitting and working out great.
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