02' engine blown!
 

I was driving casually in rush hour traffic and my boxster stalls on me. I go it towed to an independent Porsche mechanic and they did a compression test and said that the engine is toast! Of course, the surprise big ticket quote was just icing on the cake.

I thought this engine problem was reserved more for the older boxsters. Has anyone with an 02' or newer experienced this problem? Any thoughts on whether to go with a new engine or try to source a used one? Does anyone know where to look for another engine?

This is the worst news ever! And I was just starting to love my boxster! Sigh...

I am so sorry for you! Sounds like classic IMS failure.

Not to pour salt into the wound, but the mid-generation 986s and 987s are more prone to this failure than the early cars due to a redesign of the intermediate shaft.

You can now look to a 3.4L or 3.6L replacement. There's also a company in the UK which has a permanent fix to the problem and this may also be an option being a commonwealth country and all. See: http://www.autofarm.co.uk/index . Good Luck!

I'm curious to find out the cause of the engine replacement.....

I can find anything on that webpage. It keeps on going back to the home page. What kind of fix do they have.

Also, does anyone know what's involved in putting a 3.4 or 3.6 replacement? Is it a straightforward drop-in? Or do I have to replace other components like the ECU? How about the transmission, can it support the larger displacement?

Any help would be appreciated.

Im curious to what happened too... Hows your coolant look? Oil? any Leaks? Will it start in Flood mode? Id say first step is to take the car to a second opinion. Also you can get a remanufactured Engine from Porsche in the sevens if you find a good dealer... the labor shouldnt cost you more than 2000, but more like 1500...

3.4 is basically a direct swap. The 3.6... not so much, although Im doing one right now. Its the swap were your 02 will need an upgrade to the 7.8... check out renntech.org for more info.

I did a search on renntech. Sounds like a lot of people are taking the engine from a 996 instead of the boxster. Is this what you meant? I was thinking of maybe taking a Boxster S engine. Anyone know which one would be easier? Pros/cons?

Sorry to hear about the news.... :eek:

I have a DIY for a 3.4 that might interest you. Unfortunately, it's too big to download as an attachment. I picked it up a while back from renntech for my future mod in the event that this happens to me. But, if you give me your email address I will send it to you or you can go to the renntech website and download it for yourself. Let me know.

Good luck with that and keep us posted! :cheers:

Thanks for posting that autofarm link. Why don't they have shops like that in the US? Not only did they eliminate all the weak points of the engine, they can bore out a 3.2l S engine to 3.7 liters! Very cool. I wonder what hp that 3.7l would have? http://www.autofarm.co.uk/engines/water_cooled/capacity

Intersting article on engine failures

http://www.autofarm.co.uk/pdf/Total911_July06.pdf

and another from Renntech:

http://www.renntech.org/forums/index.php?act=attach&type=post&id=3224

Thank-you. I pm'd you.

There is a Boxster "S" engine on ebay right now going for around $5K! That is a great price. It looks like it may be used though. Here is the link.
http://cgi.ebay.com/ebaymotors/Porsche-Boxster-S-986-3-2-L-engine-assembly-OEM_W0QQitemZ270212476286QQcmdZViewItem?hash=item2 70212476286

Sorry to hear of your misfortune.


How long have you owned the car and how many miles are on it?

I sympathize with you as my 01 engine blew in October of 07. I got a 3.2 from Jed at Silverstar Recycling and would recommend them if you do have to have one. Good luck to you.

Mike

Hey Eric,

I sent you the pdf of the DIY for a 3.4. :)



Hey Mike,

Anything to report on the 3.2 swap?? Has the swap already been completed?? I would be interested to get your thoughts on it.

:cheers:

I've had the car for almost 2 years now. Mileage is at about 60,000kms. Been good until now.

Was the process fairly easy? Did you need to upgrade anything else? Talking to my local mechanic, he thinks that my old transmission won't be able to handle a 3.2 or 3.4. Any thoughts?

DCPorsche99 and Victoreric,

Yep, the swap has been completed. A nice upgrade that I would definitely recommend. Car has a lot more oommppphhhhh, especially noticeable from about 3500-5500 RPM. From standing still, until you hit 3,000 RPM or so, I don't really notice that much of a difference, but everything above that range is a DEFINITE large difference. I haven't tested the top speed limit of the motor yet, but I never tested that either with the 2.7.

According to my installer, it was a simple swap, nothing complex. I am still using the same 5 speed transmission. I did install a new clutch kit. I can't speak to the life expectancy of the tranny as I've only had it now for about a month. My dealer didn't think that a 6 speed was necessary and actually indicated that the 5 speed would make it more fun to drive. As a 2.7, the car was a lot of fun, but now its so much better as a 3.2. It's not just me that notices the difference as my routine passengers have all commented on the increase in power.

I do have a CEL, it throws codes of P1128 & P1130, but doesn't seem to affect performance. This probably means I need to clean my MAF sensor, or it could be related to my having installed Fabspeed Cat Bypass pipes. Either way, doesn't bother me and can't see that it's causing any issues with the car. One of these days I'll get around to cleaning the MAF and see if that fixes it.

My 3.2, which included a years warranty on parts AND labor, cost me $5200.00 delivered if I remember correctly from Silver Star and no core was required.

Buy the most power you can afford!!! Good luck in your decision.

Mike

Did you ever consider a 3.4 or 3.6 and why did you end up going with a 3.2? Reading through the autofarm links about faulty engine, it seems that the earlier 3.4 also have a great chance of failure. So I'm wondering if it's worthwhile. Would the 3.2 S engine be more reliable?

victoreric, Do you know which modifications, if any, the new engine from Porsche would include?

I assume the new Porsche engine would continue with the original cylinder sleeve design so that the cracked sleeve issue may still be there?

Would the new Porsche engine have a modified intermediate shaft or the old design?

Any changes to the head design that could prevent cracked cylinder heads?

Finding the answers to these questions may be a guide as to whether to get a new Porsche engine or not. It may be worth the extra cost if these key problem areas are addressed in the new engine (notice when I say "new" I am not talking about the 987 engine, just the new crate 986 engine). Of course the Porsche warranty would be nice too.

BTW, I am sure the new engine would have the revised RMS seal.

Also, another good article on engine failures via autofarm:

http://www.autofarm.co.uk/pdf/911PW_Apr06.pdf

victoreric, sorry to hear that news, but did it ever occur to you to get your car to a dealer to get a second opinion? maybe your independant shop is correct, but it doesn't hurt to get a second opinion, especially with such an expensive repair. it's easy for the shop to just tell you that you need a whole new engine, when in reality, you might just need a repair. Just a thought. Good luck with it.

That's a good point. They said they did a compression test and 3 of the cylinders are super low. (Max 100 psi). Should I still check?

I had a 98 with 22,500 blow on me 6 months back. I finally got around to finding a 996 3.4 and sending it to Todd (member on this forum) and he just completed the swap. I'm awaiting the car to be delivered back to me sometime this weekend. It sucks to know how easy these engines go. Mine was making a clicking noise in the passenger rear tire area and full lights with CEL came on. When I saw the CEL, I had a gut feeling it was a "Change Engine Light" type of failure. Towed it to Porsche and said it was a cable tensioner failure. Long story short, needed a new engine and 10k later, I hope this last me a little longer. So I know how it feels. Good luck and will keep you posted on how the 3.4 feels when I get it back.

what size is the original engine?

It's a 2.7L engine.

So the dealer was wrong with the cable tensioner? What happened?

Victoreric,

I considered those options, but only very briefly. I don't have the mechanical ability to do the installation and modifications for those engines myself, and it would have cost me more coin then I had available. The 3.2 was the same cost as the 2.7 so for me, that was a no-brainer. If you can afford it, or can do the work yourself, then by all means, go for the largest you can make work. You are going to have a significant expense anyway that you go, so you might as well go ahead and get all the power that your pocketbook can handle.

Mike

how many miles on it? I have a 2000 2.7 w/ 70k and I cant afford to replace the motor right now since I just bought the car..

--edit I found the answer

I'm not a mechanic, but seriously, I'd at least get a second opinion before agreeing to such an expensive engine swap. There is very high incentive for the indie to tell you that you need a whole new engine (if they think you don't know squat about cars), and since it's gonna cost you a lot anyway if you do have to replace the engine, what's another little extra just to see if what they're telling you is true or not?

Just saw on another Boxster board where a guy was all worried he needed a new engine when he noticed all this smoke coming out of his engine while driving, and long story short, all he needed was a replacement of the Air/Oil separator. I can see how a dishonest indie might take the car in due to something like this and just say to an unknowing customer that they need a whole new engine. My advice for you is to get a second opinion. Good luck.

Victoreric, I live in Vancouver.... which indie gave the advice? There are good ones and less good ones(!).

It was MB Euromotors. Do you have any experience with them?

I second (third?) the "second opinion" opinion.
Except for a few $ to get the car from one to another and a few more $ for the diagnosis, what is the harm? If it was a doctor telling you you needed a new shoulder (insert part of your choice) you'd get a second opinion. This is big dollars - I'd want to be positive.

Good luck, I hope you can get it going before the nice weather. It's snowing here!

Kevin

I am not aware of any design changes in the new Porsche motors. I know my neighbors 04 went the way of the IMS.

After the engine died, I was able to pull off and get it home. I had it towed to the dealer and they told me after 3 days it was a cable tensioner that broke and ruined the engine basically. I needed a new engine was my only option. Took it to a indie shop and they said the same thing. I didn't tell the indie shop what was wrong. So now I await the 3.4L .

Victoreric, I do not know MB Euromotors. I will send you an e-mail with some names.

Wow, I can't believe this whole thing took 5 months!

Anyways, through alot of headache, I'm glad to report that my boxster is finally up and running. Long story short, I managed to find an old 3.4 engine with only 37,000 kms and did the swap. :p

glad to hear it's back and up and running!

how much did the whole swap / labor /etc COST??? US dollars??

how much faster is it than the 2.7L ????

is it just a little or is it OMFG faster.. :)

must suprise the heck out of someone in a 987 as they see an old "base" boxster blow them away.. :)

I havent driven an S, but it definitely could spank a 2.7L. I notice this especially in the corners where I gave it a bit more gas than should, then tail starts going.

Fun!!!

Happy to hear about the succesful swap. By no means am I hoping that this happens to me, but if it does I would likely try and go the same route you did. Nice work, hope you're enjoying the car again to the fullest!

how much did this swap cost you?

did you price it compared to doing the 3.4L 911 motor swap?

This is a 3.4L from a 911. I think it's about $14000, after everything.