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Everything posted by Johnnyceesred

  1. I met with the independent who's doing the work for me and he's going to sort a senior engineering/quality control contact in Stuttgart to write/e-mail to. Rgds John
  2. Hi Kelvin, Thanks for your sympathetic reply. I read your topic and hope your new engine's performing well. I too am a working man and I need the car for my business. I had a BMW M3 (3 years old, 78,000 miles, no problems) before my Porsche which blew me away when I saw it. Yes, love at first sight really happens!!! So I was used to driving performance cars for business and covering significantly more than average mileage without a hitch, It seems you and I also have something in common, red Italian motorbikes!!. We must exchange a few more details on that point, by PM perhaps? I had a l
  3. I made another very useful contact yesterday and took the faulty crank cradle to show him. He noticed that the metal was flaking off one part and I've attached two photos to show this. I'm now more convinced that the metal that was found in the sump was off this particular part. Whether it was the cause of the misfire we'll never know but I doubt it was. He also said that the grind marks in my earlier posts would definitely have been done at the factory. It looks like they were trying to grind off some material from the casting process. Also you will see from the other attached photo that an
  4. Hi Peter, I spoke to Annette Barbara Wilke in Stuttgart today and as I suspected she cannot overrule Porsche GB's decision but did take the time to listen and apologise. I also asked about getting an analysis of the cracks and score marks on the crank cradle and an explanation as why the engine suffered the symptoms with misfiring etc. She confirmed that this wasn't normal practice but if I wanted to put my request in writing and agree to pay the costs of any further analysis they would consider it. I can understand Porsche's position regarding goodwill outside of warranty as if they are
  5. Just had the feedback from the OPC. Porsche GB are rejecting any claim and refusing any goodwill and are returning the faulty crank cradle to the OPC on the basis that: - 1. My car is not currently at an OPC (although the OPC did say this was a weak point of argument) 2. The mileage at 118,000 is outside of their goodwill limit of 80,000 and is excessive for the car's age (my response was to ask if in that case then they were saying that the car is not fit for purpose as an everyday business car doing around 35,000 miles per year?) 3. The car may have been on trackdays and hence subjecte
  6. Crank cradle taken to OPC on Saturday. Should be delivered to Porsche Cars GB 9th January. We'll know more when they've inspected the parts. I'm preparing myself for the fact that the parts may have to go back to Stuttgart. Rgds John
  7. Lee, Your experience with Porsche Customer Service is not disimilar to mine in the UK. Their standard response is that they do not speak directly with Customers on a deep technical level, they manage problem situations through the OPC network. I have tried escalating my original misfire + metal in the sump problem to the Porsche Cars GB Customer Services Director and also tried a "face-to-face" approach as I'm often in the area where Porsche GB HQ is, though with no positive result so far (although this did work when I had a split coolant hose out of warranty cover). I wasn't too disappointe
  8. Hi Graham, As the problem you describe: - 1. Can be started and stopped by turning on and off the A/C system 2. Doesn't vary with air circulation fan speed 3. Sounds like a bearing rumbling would back up my suggestion that it's the intake fan to suck air in for A/C cabin environment sensing function. When I had my symptoms the sound seemed to come from inside the dashboard somewhere between the driver's end of the passenger side airbag cover and the central binnacle for the A/C controls, radio etc. If you put your ear to the round aperture on the passenger side of the dashboard
  9. I had similar symptoms (although not continuous) and the OPC and I believe it was the small intake fan for the A/C system sensor on the passenger side for sensing the interior environment. The thought was some foam or trim behind the dashboard was catching on the blades. The sound was reminiscent of small ball bearings rattling in a plastic container. I just turned up the volume on the CD/radio to compensate!!! The problem seems to have fixed itself otherwise I think it woud have been dashboard removal. Hope this helps. Rgds John
  10. Only Moderators or an admin can change a topic title "after the fact". I have edited the title here. Thanks Loren, Much appreciated. Kind regards John
  11. Tomorrow I'm taking suspect parts to the OPC where I bought the car from for their lead technician to inspect and I'll upate with the results. Does anyone know if I can edit the topic name to reflect a more accurate situation? Rgds John
  12. Lee, We may have some common ground in the engine rebuild/replacement question and what Porsche's actions may be, if you've seen my topic Misfire 2003 996 C4S 118,000 miles. http://www.renntech.org/forums/index.php?showtopic=11615 What started out as a misfire moving from one bank of cylinders to the other which couldn't be diagnosed with certainty, has now progressed to a full engine dismantle and tomorrow I'm taking the parts in the photos in the topic to the OPC where I bought the car from to progress matters. As was stated in the replies to your topic, I think it's important to have
  13. No blame intended, only joking. I confess to looking up the Maserati web site to make sure I was spelling it correctly anyway. Is it correct about the full tank of gas to ensure correct settings?? Best regards John
  14. On a positive note, Porsche GB have confirmed that I can get the car covered by extended warranty for a year before it gets to 125,000 miles, after the faults have been found and fixed and the car inspected and passed by an OPC to the Extended Warranty standard inspection. Does anyone have any experience of the Porsche policy regarding physically inspecting a problem car to determine the nature of the problem and whether they will only do an inspection of the car (or engine/engine parts as in my case) at an OPC and not if it's at an independent specialist as mine is at the moment. Rgds J
  15. Yeah, for sure. It also looks like you guys spell Aston Martin and Maserati differently as well!!! :D :D :D Rgds John
  16. I also believe that Porsche recommend that when any alignment checks or adjustments are done, these should be with full tank of petrol. Rgds John
  17. Thanks for your response. The grinding/fettling of casting seams was favoured by the specialist as well. However my thoughts are that they are too random to be factory-based marks as I would have expected anything done at the factory to be far neater. The OPC that I purchased the car from commented that they had experienced swarf being trapped in tappets causing a misfire to move between different cylinder banks, but that was on a new car. They'd not seen swarf in a car with the high mileage that mine has done. Rgds John
  18. Hi Eben, Many thanks for your comments. When I saw the engine last week I noted there were some other gouges/grind marks on another part of the engine. I went back again today and took some more photos for comment. The photos are the same part and photographed at both the left and right ends i.e. there is gouging/grinding at both ends. We're not sure whether these are manufacturing marks or anything problem-related. I did notice that on one photo there is evidence of the metal cracking/flaking. In relation to your question, I can't say which of the two crank block halves are upper and l
  19. Hi Loren, Thankyou for your input. My concern isn't with the semi-circular bearing inserts but I'm focusing on the darker colour metal. Attached is a photo showing the difference in the profiles of the dark metal sections in one half of the crank block where the damage has occurred (the other half looks fine) i.e. some have no elongations into the alloy sections, some have one and some have 3. This is quite different to the other half of the block (see previous photos). Is this normal and do you know where there might be other photos to compare with? I hope that we can get a reasonbly q
  20. Looks like we're into very a interesting topic and I like your suggestion. I did note that the the profile of the insert on the other side of the indvidual section was not the same as the side showing either one "handle" or two "handles" i.e. the other side was similar to the other half of the crank block which had no "handles" at all. Therefore these "handles" do not span the thickness of the sections. (Hope I've explained myself adequately, photos can say so much more!!!). If the inserts are there to provide strength and higher performance characteristics (as I understand the earlier all-a
  21. The specialist cut open the oil filter after he had found a small flake of metal (possibly bearing metal i.e "white metal" or Bebbitt metal) in the sump. Nothing else was found in the filter. Also did you notice that the profiles of the inserts differed between the two halves in the thumbnail photos? I can't see why there should be "handles" in one half and not in the other. Rgds John
  22. Hi again, Glad the better photo gave you more info to assess. Any thoughts on what appear to be cracks in the darker sections? The indie hasn't mentioned finding any broken springs which was one of the early potential suggestions. Thanks for your comments on the car as well. With regard to the car itself it's my first Porsche, I was driving a M3 at the time I saw it. I had taken some time out for lunch (which is unusual for me as I often use the time to travel between clients, catching up on e-mails etc.) and chose to look around that OPC. My first words to the salesman were "I'll be hon
  23. Sorry to hear about your bad news. I hope you get a fair reaction and solution from PCNA. I'd also be interested to see if the inspection after the engine's been dismantled, reveals any similar faults as shown in my thread on my misfire problem. My fingers are crossed for you. Best regards John
  24. Hi again, I really appreciate your last 2 posts, thankyou. Regarding the difference in sound, when the problem first appeared at tickover, as you described the tone was different between the nearside exhaust affected by the misfire and the offside exhaust which seemed unaffected by any problem. Revving the engine and driving the car a short distance sounded and felt OK. This first situation resulted in a "coil pack failure" reading from the diagnostics done at the 1st OPC I took it to and so I had all 6 coil packs changed in consideration of the mileage and condition of the other 5 coil pa
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