djgross

The motor is bad and will be sent back to PCNA. Diagnosis was worn rings and bent valves. Dealer indicated possible over rev, Porsche zone rep agreed that the damage was not caused by over revs. Possible causes: Low oil or overheating (neither occurred) or a foreign object got into the engine or could be a piece of carbon dislodged from within the engine. Car had 105K miles, engine started smoking, no other signs of a problem prior to being towed to the dealer.

Duane

Hello,

I am having my engine replaced and will have the opportunity to inspect the old engine, I would like to know where the serial number is located on the engine. Also, where would I find the serial number for the engine printed in Porsche literature that came with the car.

TIA,

Duane

Tischer, what's yor exierence with Rockville?

Duane

Update:

After a phone call and a letter to the Porsche I had a phone conversation with the zone rep on Tuesday. I had sent him a history detailing the diagnosis on the car. We focused on the bore scope test because he said it was probably the next best thing to tearing down the engine; we also discussed the OBD-II report.

His conclusions were:

- The engine needs to be replace

- He stated that there was no evidence of an over rev failure

- His explained the Ignitions Range1 & 2 sections of the OBD-II report as follows

Range 1 – Is a mechanical over rev – i.e. not caused thru the gas pedal or accelerating; example was from downshifting

Range 2 – Is a serious mechanical over rev

The difference being the RPM range

- Other possible causes given:

Lack of oil

Overheating

Foreign object enter the engine

An internal part failure

- The engine failure is not consistent with a sleeve failure

I know that overheating or a lack of oil did not occur.

I am contemplating taking the car to another shop to verify the bore scope test, don’t know if I would be throwing money away. It is disappointing that the motor would go after 105K miles.

I thought you might want to know about the OBD-II over revs.

Duane

I had the same problem several years ago; the linkage was stuck. I was told by the service manager that it took 2 people a lot of effort to get back into its proper position. Your dealer should be able to fix it.

Duane

Sorry, my question was not clear enough. I should have asked, with the information presented, how could have the piston impacted the valves?

Do you think with the mileage on the car that the rings should have worn out?

Tool Pants,

Thanks again for your input.

I guess I’m a “little old lady” because I am the original owner. The car was built-in August or September of ’98. Not sure because the car is at the dealer, but I know it was one just after the summer shutdown.

Any thoughts on how the valves could be bent?

From the OBD report dated 7/16/04:

Boxster (986) DME Vehicle data

Number of ignitions, range 1

636 1909.0h

Number of ignitions, range 2

- -

Operating hours counter

2537.7

Another note:

- The car still has the original clutch

Tool Pants

Sorry for the long post, here is why I want to know.

- I have been told that my engine needs to be replaced. The dealer’s diagnosis has progressed from a leaking oil separator, (white smoke from the exhaust) to bad rings to bad rings, bent valves and cylinder wall damage.

- The car has been at the dealer for 11 weeks. From my perspective the information I have been given has changed over that time. I am trying to find out if there is a paper trail that objectively traces the diagnosis and work performed on the car.

- I have owned several vehicles with higher mileage and not encountered these problems. The car has 105K miles; it has never been to the track, DE or other type of event. It has been a daily driver, mostly highway miles. I have followed the recommendations to not exceed 4,000 RPM until the engine reaches operating temperature. All scheduled maintenance has been performed at a dealership. I do not drive the car hard; I have averaged around 30K miles on each set of tires.

- The car was fixed and running well at one point, the dealer wanted one more person to drive it. During this test drive the car started smoking again and had to be towed back to the dealer. This is when the bad rings were diagnosed and I was told that the motor needed to be replaced.

- I asked for a meeting to discuss the issue. It was agreed that a bore scope test would be performed. Here is the diagnosis:

Cylinder:

- 1: Good cylinder

- 2: Large half moon gouges in cylinder, shows signs of small cracks in cylinder

- 3: Good cylinder

- 4: 2 half moons on pistons, cylinder wall is scorched

- 5: Good cylinder

- 6: Small single half moon on piston-slight scoring on cylinder wall

Analysis:

- Rings are worn-but not completely failed.

- Bore scope traced piston to valve contact - causing bent valves to misread fuel/air mixtures - thinks its getting to much air because valves are not seating properly. Cylinder 2 is the worst, followed by 4 and 6 - with cylinder wall damage.

- Cause: Over rev-or close to over rev condition/possible miss-shift

- Ring failure can be gradual/but can also show rapid declination

- Recommendation: replace engine-complete

Compression test:

1: 125

2: 110

3: 150

4: 125

5: 125

6: 150

- It is disturbing to me that with the turn of a key a car can go from running fine to needing to replace the motor. From what I know I should have seen oil burning and been adding oil on a regular basis. I also should have noticed a drop in performance.

- I’m trying to determine if something could have occurred at the dealership that may have taken minor problem to a major problem.

Any insight you may offer would be appreciated.

Thanks,

Duane

I am researching OBD-II reports: What I would like to know is:

- What information is contained in them?

- Is some of the data permanent or can all of it be erased?

- Would a dealer generally keep a permanent record of each report made so that a history is maintained?

- Does Porsche receive a copy of the reports?

- Is there any information available on how to read a report?

Thanks,

Duane

Tool Pants,

Thanks for the reply.

Do you know what year the oil separator was changed. The dealer indicated that some part of the separator changed from horizontal to vertical. The service tech said that my 99 had the newer type.

Thanks,

Duane

Hello,

Does anyone know when the re-designed oil separator was first used on the assembly line. I have a 99 built in Aug or Sept of 1998.

I have a problem that may be related to the oil separator; I am trying to confirm some information given to me by the dealer. At the moment I would prefer to not go any further into the matter.

Thanks,

Duane