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I think I have researched this as much as it can be researched online and by calling Porsche NA. From my "research", the issue was definitely worse in the 97-99 (first half) model years for the Boxster engine. The casting of the blocks was subbed out, and some of them were porous, some were not. There was to be a quality control inspector of all of the engines/blocks, but I don't know how that person could inspect the inside of casted metal to know if there were bubbles/etc. that could eventually leak. I suppose that could be done with x-ray technology or laser scanning (as is done with underground petroleum tanks for instance), but I don't know if Porsche did/does that or not.
Our local Porsche tech told me that they replaced "several" engines in the 97-99's, and Porsche paid for all of the ones under warranty. I am buying a 97, and because of the issue, I got it inspected and am purchasing the maintenance agreement. It will cost me $800/year, but I don't want to absorb a $12K (minimum)engine hit. As I understand also, there is not a "fix". Once the porous block issue occurs, it allows the gas and oil to mix and you may start to notice a sludge in the coolant check port, though I have read posts that say that there was no warning, just "catastrophic engine failure" to use one of our forum member's terms.
What happened to make the problem go away in 99? I can't find that information anywhere, but welcome it if any of our other members know the answer. Sleeving the cylinders in an attempt to fix leaks was apparently another major disaster, as the sleeves would come loose from the remaining outer portion due to improper seating problems, and then simply "seize up." Ouch.
If you put "porous block problems" (and don't specifically ask for Porsche), into your internet search engine, you will quickly find that it is not a unique problem to Porsche. Land Rover had big problems with it, as has Ford and Chevrolet. Many of them blame the "outsourcing" of casting and poor quality control, others don't blame or take blame. I guess we just hope that our motor got inspected, and gamble or not gamble with a maintenance contract if your car will pass the inspection, which certainly isn't a given. The other issue is maintenance agreements. They can be a curse or godsend. I am buying the one that our Porsche dealership reccs. just so they do the hassling with them, not me. Also, there are alot of fly by night sellers of maintenance agreements I am told, and when you turn in a claim, they are busted. se la vi when you are selling risk contracts.
Best to all.
Thom
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