Had to replace the engine in my '01 S

[Geof3]

I think sometimes those are also referred to as “galley” plugs. Could be wrong in this particular application. Interesting failure though. Would like to see some other input. I wonder if your crankcase pressures got to high and blew it out?

[BYprodriver]

Originally Posted by Geof3

I think sometimes those are also referred to as “galley” plugs. Could be wrong in this particular application. Interesting failure though. Would like to see some other input. I wonder if your crankcase pressures got to high and blew it out?

Correct name is expansion plug

[maytag]

Originally Posted by BYprodriver

Correct name is expansion plug

Please clarify: are you stating that this particular plug is an expansion plug?

Expansion plug, galley plug, casting plug: these are the 3 different things that frequently look the same, but are used for different reasons. They are not terms that should be used interchangeably (though they often are, even by me, haha)

So if you're telling us that in this case it is an expansion plug, that'd possibly be useful in helping the O.P. understand the failure.

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[MWS]

Originally Posted by maytag

Expansion plug, galley plug, casting plug: these are the 3 different things that frequently look the same, but are used for different reasons. They are not terms that should be used interchangeably (though they often are, even by me, haha)

Well, I've learned something today...looks like I've got some googling to do.

[911monty]

As if more reasons were needed for sleepless nights we now have this. What is an otherwise fine looking "freeze plug" haha was pushed out of it's bore due to a bunch of overexcited molecules, the question then is did this car have a genuine OEM ending in .04 coolant cap, god forbid, or an aftermarket cap??????

Edit You do have to admire the German's environmental consciousness for capturing the coolant in the engine crankcase..

[maytag]

Originally Posted by MWS

Well, I've learned something today...looks like I've got some googling to do.

So, I should start prefacing my comments with "as far as I know", or something like that. I don't mean to be the guy who knows more than everybody about everything. pfft.

So, as far as I know, the differences are thus:

Expansion-Plug (Also called a freeze-plug)= used to protect larger castings where the stresses that may occur threaten to break the casting. A hole is cast-in to allow for expansion / contraction, and the plug fills that hole. These stresses are (in my experience) usually thermal, and especially about freezing, but they can also be about torsional forces in a stressed-member.

galley plug = These are used as a convenience / access to areas requiring machining, POST-Casting. An example is when an orifice must be drilled at the bottom of a casting, a hole will be cast (or bored) to allow tool-access, and then plugged with the galley-plug. In MANY motors the oil passageways are drilled / bored through the block, and then sealed at the tooling-end with a galley plug.

Casting Plug (Also called a "core-plug") = During the casting process, holes are required as a convenience for removing media after the casting has cooled. They serve no other purpose afterwards, but are an unfortunate limitation of casting methods. These holes are plugged with a casting-plug, or core-plug.

So here's why it matters in respect to the photos: Which type of orifice is being filled with that plug would help to determine potential causes of failure. This is why I noted that I am not the Porsche Expert.
But is this a galley-plug? if so, it shouldn't fail. But I have, on occasion, tapped them for a threaded-plug, to dismiss the possibility.
Is it an expansion plug? Was the motor exposed to some extreme temperatures? Especially freezing?
If it's a casting-plug, then the only likely source of failure is faulty installation.

That's what I know.... as far as I know it. YMMV, I guess.

[DSmith]

I thought it was freeze plug but I have never seen a freeze on the inside of an engine, but I have never seen the inside of a Porsche either.

Thanks for all of the replys.

It did not have the -04 coolant cap but it had the original. It has the -04 now.