Engine Failure - Help, What do I do?

[dgentileksu]

You have my deepest empathy on this one...

I just bought my 98 box last week and have it going in on Monday to repair a leaking coolant tank, get a new clutch and replace a leaking RMS...

Do any of the members on this forum know how common these total engine failures are? I love this car, but these issues are causing me to wonder if this buy was a good idea...

Any thoughts?

[easyc]

From my understanding the cylinder sleeve dis-forming (shifting and etc) was a early engine problem... the cracking is a new problem that has started to come along now that the early 3.4's (from 996), 3.2's and 2.7's are getting up in miles

I wouldn't say this is a big problem, as I would guess a good percentage (25% or so) will get on a message board to tell their story... the M96 engines do die... but a lot of engines die too....

[Brucelee]

We have no real data on this save the posts. We are not alone, this issue has made the Porsche magazines too, so we know IMS issues still persist.

Only Porsche knows and they are not talking.

[Lil bastard]

As these cars accumulate higher and higher mileage, some different problems are starting to crop up such as cracking of the Cylinder Liners, most often, the #2 and #5 cylinders.

This is thought to occur because the mettalurgy becomes more brittle after long-term heat cycling (or excessive overheating - watch that cooling system, especially cleaning the radiators and insuring your fans operate correctly) and the slight torqueing the engine experiences (a good reason not to ignore the condition of your motor and transmission mounts).

Usually beginning as parallel cracks at the top of the liner, these often join further down the liner. When engine torque is applied, a 'D' shaped chip can break off the top of the liner. Somewhere in this process the integrity of the water jacket goes away allowing coolant to enter the cylinder creating Hydrolock, or allowing the coolant/oil mixture to attack the Main or Rod bearings.

Often this is the cause, but it frequently goes undiscovered because the diagnosis of Engine Replacement is made w/o a total dismantling of the engine and is attributed to other issues such as timing chains etc. which may in fact be secondary failures caused by the bad cylinder liners.

[Brucelee]

That is bizarre. No my cousin's Lexus SC400 is coming up on 300K miles. Original engine, used only DINO oil and not very good about getting it changed.

Runs like the day she bought it in 1992. I had a SC400 with 180K on it that ran like new also.


Hmmmm.

[thenavarro]

Sorry for your situation. I had to have a total engine replacement in my 01 as well a few months back. Still fighting with the warranty company over it as a matter of fact.

I would recommend SilverStar Recycling in California, if you are going to buy a used engine. They were great to work with in my situation. I bought a used 3.2 from them.

Good luck!!

Mike

[silver arrow]

If it was a Subaru motor that had been overboosted I would say to get some Darton sleeves put in the thing and rebuild the bottom end. So why again does everyone buy an entirely new engine for these things? Any reason these things can't just be rebuilt.

[Brucelee]

Originally Posted by silver arrow

If it was a Subaru motor that had been overboosted I would say to get some Darton sleeves put in the thing and rebuild the bottom end. So why again does everyone buy an entirely new engine for these things? Any reason these things can't just be rebuilt.

As I understand it, Porsche does everything in its power to restrict this kind of action. Not sure how that translates but you rarely find anyone rebuilding these motors (maybe never) or pulling it apart to build a face motor.

The more racing oriented here can chime in on this.

[Brucelee]

I just visited Roadfly and typed in Blown Boxster engine in the search window.

OH MY GOD.

I am speechless.

[Brucelee]

It seems that there are more parts available for the older air cooled Porsche engines. However, the issue may indeed be the block. Notice the top and bottom end parts but if the alloy block is whacked, what do youi do about that?

I have not come across any sleeving parts and maybe that isn't even doable given the characteristics of the block.

Hmmm.







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Porsche 996 & Boxster Call For Details

[Brucelee]

If you want an eye-opener, simply Google Boxer engine failures.

Wow, baby!

I own a 1999 C2 996 Manual (3.4 engine) which was originally bought from an Official Porsche Centre in the UK and all services have been carried out by OPCs since.

It has had an engine and transmission replaced already due to internal component failures. It has had the usual leaking RMS problems.

Recently the car went in for its annual service. The car was fine when it left me and but after the service had been carried out and during the final road test I was told that it developed a major engine problem which has subsequently been diagnosed as a big end bearing failure which requires another engine replacement.

The car is now out of warranty and I have been informed by PCGB that because of this and the age and mileage of the car, they will not cover the costs. They have offered to make a contribution, but I’m still facing a very big bill.

There is plenty of information around on forums about the RMS oil leaks and engine failures due to liners cracking and bearings breaking up in 996s and Boxsters. Transmissions also seem to be a problem. Some owners have received 'goodwill' FOC replacements and others have been left to pick up the bill. Is this just a case of who shouts loudest or complains the most gets the goodwill and rest are left to find more money to pour into a car which has already depreciated more than any almost any other Porsche model in history?

I do not want to be a cause of further depreciation but isn’t it about time something was done about this situation? If the number of failures occurring is a small percentage then it would be in Porsche’s interest to simply replace them FOC and keep their customers happy. If it is such a big issue that they don’t want to spend the money doing this, we all should be made aware.

A few people in the past have tried to gather information, set up websites etc. to bring this out into the open but don’t seem to have got very far. I would like to do something not just to sort out my own situation but also to help all 996 and Boxster owners, past and present, receive fair treatment from Porsche.

To start with I'd like to hear your stories, good and bad. So if you've suffered an engine or transmission failure with your 996 or Boxster, please let me know the VIN/chassis number, year, model and mileage when it happened, description of fault/failure and what the result was (warranty replacement, goodwill replacement, contribution or no help given).

Please post here or e-mail me privately:

mrphish@dial.pipex.com

All personal information will be treated in the strictest confidence. No names or e-mail addresses will be released to anyone without the consent of the contributor.

Please feel free to copy or e-mail this post to anyone you know who has had engine or transmission failures and help get the truth out in the open.

[Lil bastard]

Originally Posted by Brucelee

As I understand it, Porsche does everything in its power to restrict this kind of action. Not sure how that translates but you rarely find anyone rebuilding these motors (maybe never) or pulling it apart to build a face motor.

The more racing oriented here can chime in on this.

It does require quite a few special tools. While there don't seem to be many rebuilders here in the states, a brit firm called Autofarm does quite a job rebuilding them and in fact making them better - http://www.autofarm.co.uk/

[2001saxster]

Yesterday i received the maintainence history of my vehical which was sent to me from the dealer I bought it from. This is basically the cars history from before I bought it. Does anyone know what the following mean and if they might have any bearing on or been an indication of future engine failure?

13poz engine elictrical
14pozce check engine light (2 times within 1 week this appears)
22poz driveshaft/diff
11poz engine repair mi

I am particularly interested in the last two because they happened one month (or less) prior to me purchasing the vehical. I think maybe the very last one was done after the vehical was traded in because there is also a line for buyers guide and detailing, but none for a loaner car. Again, any help would be very much appreciated. I as told the car was tip top with no past problems.

[Frank M]

Originally Posted by 2001saxster

Yesterday i received the maintainence history of my vehical which was sent to me from the dealer I bought it from. 13poz engine elictrical
14pozce check engine light (2 times within 1 week this appears)
22poz driveshaft/diff
11poz engine repair mi.

If anyone is to decipher what could have been related to your failure, we would need to know the specifics of that repair.

[2001saxster]

Originally Posted by Brucelee

As I understand it, Porsche does everything in its power to restrict this kind of action. Not sure how that translates but you rarely find anyone rebuilding these motors (maybe never) or pulling it apart to build a face motor.

The more racing oriented here can chime in on this.

So where are these re-manufactured engines the dealers are selling coming from then? It sounds to me like Porsche's policy is to recommend replacement for any engine problem (even if a full dignosis can't be made because they don't want to fully inspect it), then send that engine back to the factory to be rebuilt for the next unlucky Porsche driver to buy for another $10,000. They are probably making a good buck doing after warranty replacements on their faulty design.

[Brucelee]

Originally Posted by 2001saxster

So where are these re-manufactured engines the dealers are selling coming from then? It sounds to me like Porsche's policy is to recommend replacement for any engine problem (even if a full dignosis can't be made because they don't want to fully inspect it), then send that engine back to the factory to be rebuilt for the next unlucky Porsche driver to buy for another $10,000. They are probably making a good buck doing after warranty replacements on their faulty design.

The dealers source them from Porsche Germany. They are essentially new engines, with the reuse of some external parts, like injectors, intake and exhaust. Those parts are remanunfactured.