A 968 engine swap story (long)
10-28-2003, 04:00 PM
#1
Race Car
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A 968 engine swap story (long)
(a drum roll please) Introducing my 1987 944na -- with a second lease on life and a new designation '944S3'.
Little background info: over this summer, my girlfriend and I drove this 1987 944na with 110K miles, my daily driver, from San Francisco to Boston (for a temporary job in Boston). Gotta love the 944 -- so much cargo room and so fun to drive -- perfect for those long road-trips. During the trip, we started experiencing overheating problems in Pennsylvania. I'm pretty sure it had something to do with the 36 hours of non-stop endurance driving from Wyoming to Ohio.... We basically got as far as Connecticut before getting towed the final 150 miles to Boston.
Here's a picture of the engine as we got towed into Boston:
Yes -- that is duct-tape on the upper radiator hose!
The vehicle was taken to Kevin at Randolph Racing. I had him pull the engine for a look, and we had basically blown the head gasket and scorched the #3 cylinder. I was already looking at either 1) junking the car, 2) rebuild the engine with an oversized cylinder or 3) a new engine. Junking the car would have been the 'right thing' to do, but that was not an acceptable option -- I was not going to be the man who killed my Porsche by driving her across the country. So, I figure I'd go with 4) 968 engine swap b/c that was the fun thing to do. I've done some minor DIY work before (belts, AC recharge, new steering rack) but nothing major. Since I also don't have the space to work on cars in Boston, I chose to have the shop do all the work.
First, I sourced a complete 968 motor (included DME, harness, water pump, alternator, etc) with 70K miles from PartsHeaven for $4500 plus $225 shipping. Bit expensive but it's a reputable source. It turned out that the motor needed a new headgasket and PartsHeaven paid for that repair -- many thanks to Al at PartsHeaven for standing behind his goods! Had I bought an engine elsewhere, it would have been 'as is'. Also needed a 944S2 flywheel (which needed refacing) and a K&N air filter. Just to be sure, we updated to a 951 radiator, installed an external oil cooler, and replaced the clutch (the car had the original rubber center-type clutch). Since we were at it, we called in for new belts, motor mounts, thermostat, engine seal, fixed a leaky brake cylinder, valve job, etc, etc... Might as well do a complete overhaul since you're there. Grand total (w/o engine) right at $6000 -- I was hoping we'd do the job for less, but considering the amount of work done, I'm quite satisfied.
Here's the new engine:
How does she drive? The 968 engine mated to a 944 tranny is absolute fun! The power of a 968 and the shorter gearing make you just leap out in the first two gears. At higher speeds, the 944na could never pass cars aggressively nor climb steep hills fast -- it was very painful through some of those mountain passes. Now that has all changed -- easy highway passing and hill climbing. There are still some minor tweeks to be worked out, but it feels like an entirely new vehicle. Future plans for my former daily driver: some suspension work, better brains behind the wheel (Driver Eds), lighten the vehicle load (gym memberships).
Little background info: over this summer, my girlfriend and I drove this 1987 944na with 110K miles, my daily driver, from San Francisco to Boston (for a temporary job in Boston). Gotta love the 944 -- so much cargo room and so fun to drive -- perfect for those long road-trips. During the trip, we started experiencing overheating problems in Pennsylvania. I'm pretty sure it had something to do with the 36 hours of non-stop endurance driving from Wyoming to Ohio.... We basically got as far as Connecticut before getting towed the final 150 miles to Boston.
Here's a picture of the engine as we got towed into Boston:
Yes -- that is duct-tape on the upper radiator hose!
The vehicle was taken to Kevin at Randolph Racing. I had him pull the engine for a look, and we had basically blown the head gasket and scorched the #3 cylinder. I was already looking at either 1) junking the car, 2) rebuild the engine with an oversized cylinder or 3) a new engine. Junking the car would have been the 'right thing' to do, but that was not an acceptable option -- I was not going to be the man who killed my Porsche by driving her across the country. So, I figure I'd go with 4) 968 engine swap b/c that was the fun thing to do. I've done some minor DIY work before (belts, AC recharge, new steering rack) but nothing major. Since I also don't have the space to work on cars in Boston, I chose to have the shop do all the work.
First, I sourced a complete 968 motor (included DME, harness, water pump, alternator, etc) with 70K miles from PartsHeaven for $4500 plus $225 shipping. Bit expensive but it's a reputable source. It turned out that the motor needed a new headgasket and PartsHeaven paid for that repair -- many thanks to Al at PartsHeaven for standing behind his goods! Had I bought an engine elsewhere, it would have been 'as is'. Also needed a 944S2 flywheel (which needed refacing) and a K&N air filter. Just to be sure, we updated to a 951 radiator, installed an external oil cooler, and replaced the clutch (the car had the original rubber center-type clutch). Since we were at it, we called in for new belts, motor mounts, thermostat, engine seal, fixed a leaky brake cylinder, valve job, etc, etc... Might as well do a complete overhaul since you're there. Grand total (w/o engine) right at $6000 -- I was hoping we'd do the job for less, but considering the amount of work done, I'm quite satisfied.
Here's the new engine:
How does she drive? The 968 engine mated to a 944 tranny is absolute fun! The power of a 968 and the shorter gearing make you just leap out in the first two gears. At higher speeds, the 944na could never pass cars aggressively nor climb steep hills fast -- it was very painful through some of those mountain passes. Now that has all changed -- easy highway passing and hill climbing. There are still some minor tweeks to be worked out, but it feels like an entirely new vehicle. Future plans for my former daily driver: some suspension work, better brains behind the wheel (Driver Eds), lighten the vehicle load (gym memberships).
10-28-2003, 04:05 PM
#2
Joe - is that 10.5K plus the car? If so I think you now own the most expensive 944NA on this board!
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10-28-2003, 04:09 PM
#3
Burning Brakes
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Awesome, this is my dream swap!
I wonder how much heavier is the new engine? Afterall, adding more weight up front will introduce understeer, unless the suspension is retuned.
Does it still handle neutral?
Stan
I wonder how much heavier is the new engine? Afterall, adding more weight up front will introduce understeer, unless the suspension is retuned.
Does it still handle neutral?
Stan
10-28-2003, 04:19 PM
#6
Race Car
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is that 10.5K plus the car?
I hadn't notice much handling difference yet -- but I've only been going around town so far. If anything, the car used to oversteer, and still oversteers.
10-28-2003, 04:35 PM
#7
Just seems like alot of money on an NA 944. I can understand though. I parted with my first 944NA for about 1/10of of what I had in it.
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10-28-2003, 05:24 PM
#10
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To be precise, I mean how scary it is to pass an RV that you've been stuck behind for the past 5 miles at the only passing zone for the next 10 miles on a mountain road when you can see the bright headlights of an oncoming tractor-trailer truck on the other lane. 
10-28-2003, 08:48 PM
#12
Three Wheelin'
Joe:
WOW is all i can say. Congrats on the work! I have to admit this swap is also on my mind...i have an 87 924S and i will prolly have access to a complete 968 engine next spring. So the thought has crossed my mind....
I already changed over my clutch to the spring style last year. So you changed the flywheel to an S2 Style? Was there a need for that, does the dual mass not work?
...i guess id have a 924S2 then huh?
Goodluck Joe!
Erich Schmidt
WOW is all i can say. Congrats on the work! I have to admit this swap is also on my mind...i have an 87 924S and i will prolly have access to a complete 968 engine next spring. So the thought has crossed my mind....
I already changed over my clutch to the spring style last year. So you changed the flywheel to an S2 Style? Was there a need for that, does the dual mass not work?
...i guess id have a 924S2 then huh?
Goodluck Joe!
Erich Schmidt
