Porsche Boxster S 987 3.2 Engine Rebuild/ Problems

[mda00mjc]

Hi All

I thought I would share my experiences of ownership of my 987 Boxster S 3.2 2005 with 64000 miles.

I purchased the car a year ago from Porsche with a 1 year warranty. I went for the 111 point check to extend the warranty a month ago when they herd a ticking noise coming from the engine - this can be herd below.

http://www.youtube.com/watch?v=kFCylXD4Y1g

Initially Porsche OPC Leicester removed the engine and did cylinder tests which came back ok. They felt that the tappets were a fault and replaced these with new seals.

The engine was reinstalled in the car but the noise persisted.

After discussion with Porsche UK Reading and Stuttgart the engine was once again removed and stripped. They identified a problem with one of the pistons (the cylinders are ok) and are rebuilding one side of the engine 4,5 and 6. with new cylinders and pistons.

Porsche OPC Leicester have been good thus far and have given me a new 2010 PDK Boxster as a courtesy car for 3 weeks.

I would appreciate any comments with regard to the repair, is a half engine rebuild ok or should the whole engine be repaired or replaced?

I am a bit worried if the other side of the engine hasn't been replaced what is the chance of a problem with this?

This will all be free due to the warranty which I believe is invaluable for these cars if they qualify for one.

If outside of the period I would probably go with Hartech.

Mike

[porka911t]

I rebuild engines for my living and if the other bank of pistons are all good then I see no problem with the repair they are doing, I wonder if they are fitting the upgraded IMS at the same time ?
I doubt it may be worth paying for the parts if they would agree to fit them.

It just goes to show it is worth buying the approved warranty as this would have cost you 5-6 k I bet.

[mda00mjc]

Thanks for that

They have said they aren't replacing the IMS and say I would be wasting my money to pay for one as the 3.2 987 didn't suffer this problem and mine looks ok.

Though other people have suggested this,what do you think?

[sportsandclassic]

Hello,

That noise does not sound piston speed related..? It does sound cam-shaft/tappet speed.

As for just rebuilding 1 side of the engine that is impossible as if the piston and liner are at fault it will need a new crankcasing as the liners are not available loose... so at least it gets new liners and a few pistons. I would at least want the pistons measuring and new rings fitting minimum.

Mike

[mda00mjc]

Thanks Mike

This was what Porsche OPC leicester emailed me

"We are replacing pistons 4-6, big end shells & little end bearings this is where the problem is emanating from. "

They also said they were replacing the cylinders.

Is this not possible? Would they have to do both sides of the engine?

Mike

[yellowgriff]

Just listened to your youtube vid & dont think it sounded that bad, Sound more like exhaust blow than something terminal with engine,, I own car bodyshops not mecanical shop but this doesnt sound like bottom end noise in my experience, Hope im wrong & they are right for your sake,,,

[sportsandclassic]

Hi,

so what are they saying is wrong as they do not seem to be replacing the liner (crank casing) ?

Mike

[mda00mjc]

I'm not entirely sure they keep telling me different things which is a bit odd.

[mda00mjc]

I've got a reply as to what the problem is and whats being replaced

"The liners are part of the crankcase, the crankcase is not being replaced. We are replacing pistons 4-6, big end shells & little end bearings, the little end bearing is where we believe the problem is emanating from. We believe that there was excess wear between No 5 piston pin and the little end bearing"

Any thoughts?

[Pope]

No problem with what they are saying; if the noise is small end bearing / piston pin then they'll replace what's necessary and rebuild the engine. The work will be covered till the end of the remaining warranty period and you'll have the opportunity to rewarrant the vehicle come renewal time. As long as the noise is gone once it's sorted, happy days.

[mda00mjc]

Thanks

[mda00mjc]

I'm looking forward to getting my Boxster back on tuesday.

Half of the engine 4,5 and 6 has been rebuilt due to piston and little end bearing wear.

Are there any special precautions needed when I get the car back?

[Trev450]

Go with whatever advice the OPC give you and then you're covered if any future issues occur.

[khushy]

Trev450 said:

Go with whatever advice the OPC give you and then you're covered if any future issues occur.

exactly and well done OPC Leicester.

Hope you enjoy having your car back.

khushy

[mda00mjc]

I'll wait until i get the car back but they have done a good thorough job.

Martyn in services has been excellent.

[mda00mjc]

Hi All

I have received the car back from Porsche OPC leicester after its half engine rebuild. I have been impressed with their service and customer relations during the process.

Unfortunately the intermittent engine ticking noise seems to be similar/ the same as before. I have recorded the pre and post repair noises for people to view below.


Pre

http://www.youtube.com/watch?v=kFCylXD4Y1g

Post

http://www.youtube.com/watch?v=iGunVRUnyHs

What do people think? I've also noticed that the coolant level although not under minimum is around 1/4 full. I have read that small coolant leeks can be a sign of engine problems?

I have spoken to Porsche Leicester who have advised me to keep an eye on the noise and want to check the car over in 2 weeks.

Any thoughts?

[Soovy]

So you're impressed, but they haven't fixed it?

WTF!

[Magic919]

Not even sure how you'd keep your eye on a noise.

Doesn't sound good from the video. I'm not sure I'd have left with the car, TBH. Hope you can get it sorted.

[mda00mjc]

What would people advise me to do?

[Soovy]

mda00mjc said:

What would people advise me to do?

Take it to another OPC.