Engine Installation
The 06A VAG 20V engine shares generational traits with the Porsche M96 engine, allowing for seamless electronic integration entirely within the engine harness. Mechanical integration is equally efficient, utilizing the original Boxster transmission coupled with the minimum number of bespoke components necessary, opting for off-the-shelf (OTS) aftermarket or OEM parts to simplify the supply chain wherever possible.
This engine repower maintains the original Porsche engine mounts to preserve the vehicle's inherent noise, vibration, and harshness (NVH) levels. The engine placement and mount mass is calculated to minimize effects on vehicle balance and the center of gravity (CofG).
Additionally, the repower is designed to integrate with the Porsche's existing cooling system at the entry to the engine bay via a modified aftermarket silicone hose kit and a small number of generic hoses. Standard 986 coolant radiators are sufficient for power outputs up to 400bhp, with the capability to support up to 500bhp when enhanced with drop-in aftermarket performance parts. Intake charge air cooling can be achieved with either air/air or air/water solutions depending on the power/cooling requirement.
Bolt On Component Modification
Modifications to allow for engine fitment are achieved entirely through changes to bolt-on components, specifically the cross member and gearbox mounting arms are modified via weld-in, laser-cut, and precision-formed parts.
Pre-formed parts dramatically streamline the modification process of these components while ensuring accuracy and minimising time spent. Comprehensive documentation is provided to guide the modification procedure.
The alterations accommodate the taller profile of the 06A 20V engine relative to the original M96 engine. Finite Element Analysis (FEA) has been applied to confirm that the modified components maintain the same level of rigidity, strength, and failure mode integrity as the original parts. Additionally, the gearbox mounting arms are uprated as a result of this process to handle the increased torque output of the repower.
Engine Fitting Process
The process of fitting the 06A 20V engine once it has been fitted with the kit components is extremely straight forward. The engine and gearbox are mated and the two components are fitted as an assembly. The assembly can be lifted into position with the front engine mount attached allowing easy alignment with the chassis hard points. The gearbox mounts are then bolted into position and the lifting gear removed accordingly.
Fitting with the kit components is no more difficult than fitting the standard M96 engine and gearbox combination.
A flat lifting trolley is highly recommended to make the process of removing the standard engine and fitting the 06A engine as easy as possible. These can be rented at low cost and the M96 engine removed and 06A engine fitted across a weekend.
