Don't wait until your engine blows up to make some necessary upgrades
Long, reliable engine life
This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster. The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads. With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details.
Check out some other sample projects from the book:
Using the expertise gained from years of designing and building engines, Porsche developed what is known as the M96 engine for the introduction of the Boxster in 1996. The horizontally opposed engine was developed with a throwback to the traditionally air cooled motors, having kept the opposing cylinder or boxer layout. The engine was designed from the outset with the goal of providing a common platform for both the Boxster and the upcoming Porsche Carrera. The motor was indeed scalable, encompassing a displacement that ranged from 2.5 liters all the way up to 3.8 liters at the end of its production run.
The M96 (and subsequent similar M97) water-cooled engine is definitely a strong performing engine, however along the stages of its development it has suffered from some design deficiencies that have been identified and corrected by Porsche over the 11 year lifespan of the engine. It's not uncommon to find a car listed for sale with new factory engine recently installed in the advertisement. No one but Porsche knows exactly how many engines were replaced under its recently discontinued engine exchange program. However, simply swapping out a broken engine for another one does not address known weaknesses in the engine due to design deficiencies. The purpose of this project is to identify some of the problem areas of the engine and offer up solutions on how to fix and/or prevent any damage from happening to your engine.
Rear Main Seal Leaks: When the M96 engine first came out, it was perhaps most known for its rear main seal (RMS) leaks. While some of the RMS problems were probably actually intermediate shaft cover leaks (see next section), there were definitely some problems with the seals on the early cars. For the most part this was a cosmetic issue, as the leaks did not tend to affect performance, unless they became so severe that they began to affect the proper operation of the clutch. But many engines were torn apart and/or replaced by Porsche under warranty due to this problem because when you pay $75,000 for a high performance sports car, you expect it not to leak.
It's not really 100% clear what the causes the leaky rear main seals. One cause may possibly be the fact that the crankshaft has insufficient support on the rear end. It also may be caused by the fact that the crankshaft carrier support is only pinned minimally in one plane to the outer case. This can lead to shuffling of the carrier: shuffle pinning the crankshaft carrier as is commonly done when prepping an early 911 engine for the track can help the problem.
The seal has been updated to a 997 Cayenne-style part number since the engine was originally introduced, and for the most part the engines no longer leak from this area when this new and improved seal is installed. If you find that your engine is leaking from the rear main seal (also known as the flywheel seal), then simply install a new one while adding a little bit of Curil-T sealant to help keep it dry (see Photo 10 of Pelican Technical Article: Clutch Replacement).
Intermediate Shaft Bearing Failures: The intermediate shaft bearing is probably the most troublesome of all of the M96/M97 engine problems. The intermediate shaft bearing (IMS bearing), supports the intermediate shaft on the flywheel end of the motor. Porsche designed these motors using a sealed ball bearing that is pressed into the intermediate shaft. These types of bearings are typically used in devices like copy machines and other machinery used in dry conditions. In theory, the area where Porsche designed the bearing to sit is supposed to be dry. However, after years of use within the engine, it would appear that oil and contaminants from the engine seep past the bearing seal, wash out the original lubricant and become trapped inside. The result is that the bearing now operates in a less-than-ideal environment and begins to wear prematurely. When the bearing wears out, the timing chains on the engine may disengage, and the engine will quickly self-destruct. When the bearing does fail, foreign object debris from the bearing circulates throughout the engine, causing further damage to other areas in the engine.
On the early cars, Porsche also used a center bolt to secure the IMS bearing that was too weak and sometimes snapped. If this bolt breaks, then the intermediate shaft begins to float around in the bottom of the engine, and you can soon experience catastrophic engine failure.
This area is also highly prone to leaks. The seal around the intermediate shaft cover can leak, and it has since been updated and redesigned to prevent leakage. In addition, the three bolts that hold the intermediate shaft cover are through holes which exit into the cavity of the engine case. You must coat these bolts when reinstalling them in order to prevent oil from leaking out through the bolt holes. In general, if this area is leaking, it may indeed be a sign that your intermediate shaft is failing and you should inspect it immediately.
The good news is that the IMS bearing problems are all fixable, thanks in part to a retrofit kit that can be installed with the engine still in the car. See Project 14 for full instructions on how to update your engine.
Cylinder Liner Cracks: In an effort to reduce costs during production, Porsche utilized a type of insert-mold casting process to directly incorporate Lokasil cylinder liners into the case. While this is a neat way to reduce the total number of parts used in the engine, this design basically casts a wearable part into the engine case. There is no factory replacement for the liners: when they wear, the factory expects you to buy a new engine case. In addition, the design of the cylinder liners allows them to float within an area filled with coolant.
Excess vibration and twisting from the normal operation of the engine appears to be causing some cracking in these liners, resulting in a small chunk of the liner breaking off. This D-chunk problem seems to ironically occur mostly in gently driven cars. Boxsters that are driven hard at the track or on the street do not tend to see this type of damage. At least with respect to the track cars, one theory is that these cars tend to have their oil changed much more often. The problem affects mostly the 2.5 and Carrera 3.4 engines: the 3.2 Boxster S engine appears to be unaffected because it has thicker cylinder walls than the 3.4 engine. When this failure happens, you will see oil and coolant begin to mix together, or a slight unexplained coolant loss.
If your engine experiences this failure, it can be rebuilt using LN Engineering's Nickasil liners installed. They take your old case, machine out the cracked or damaged Lokasil liners and install an aluminum Nickies insert which is stronger and more reliable than the factory cast-in liner. In addition, with the installation of the liners it's fairly easy to increase the bore of the cylinders which translates into increased displacement and more horsepower. If you go this route, you will also need to use some aftermarket pistons and perhaps update the software in your DME to accommodate the larger displacement.
Engine Casting Porosity: As mentioned in the previous section, Porsche used a new cost-effective method to cast in most of the oil and water cooling passages directly into the engine case. This reduced the total part count for the engine, and also helped to reduce assembly time and production cost. Unfortunately, the advanced casting technique seems to have led to a number of engine cases experiencing what has been called engine porosity. There is not a lot of information available on this problem, but it seems to be related to problems with the initial casting process.
In some cases, there appeared to have been a leak through the internal crank case walls. The process of pouring the molten aluminum must be tightly controlled, otherwise pockets of air forming in the aluminum may result. Most of the time, post-casting inspections will reveal these flaws, but apparently some were still manufactured into running engines. The result is that oil and water became mixed within these engines. This resulted in coolant being found within the oil (turning it a milky brown color), or oil being found inside the coolant tank.
The expansion and contraction of the engine due to the heat of normal operation can expose this problem as well. I have also heard of engines that simply weeped a slow bead of oil right through the walls of the engine case when running. Unfortunately, there's nothing that can be done to fix this problem, short of scraping the engine. The good news is that most of these problems were discovered on the cars when they were new, and the engines were since replaced under warranty.
Chain Tensioner Failures: There's been some chatter lately about chain tensioners failing on some of the M96 motors. If your car is noisy on startup and then suddenly quiets down, it may indicate a problem with your chain tensioners. Porsche updated the design of the tensioners in 2000 (TSB Group 1 NR 8/00), and replaced them with an improved design. I recommend that you update and replace your chain tensioners if they are the older style. See Project 16 for more information on how to identify and replace them.
Cylinder Head Cracks: In general, the cylinder heads are pretty well designed on the M96 engine. However, on some 3.2, 3.4 and 3.6 engines, small cracks can sometimes develop around the seats of exhaust valves and extend to the spark plug hole. The mounting point for the cam follower housing is also a weak point. Often these cracks can lead to coolant and oil mixing together. This is not an uncommon problem with automotive cylinder heads in general and can often be repaired by a skilled machine shop that can weld aluminum heads.
Oil System Inadequacy: The air cooled predecessor to the M96 engine incorporated a dry-sump system that was designed to keep a significant amount of oil in reserve for extended performance driving. With the introduction of the M96 engine, Porsche moved away from that design, primarily due to the high cost of implementing a separate dry sump system. The M96/M97 motors instead were designed with a compromise system, which has an oil sump built into the bottom of the engine: a kind of hybrid between a dedicated dry sump system and a typical wet sump. As a result of the lower oil holding capacity and other factors, the M96/M97 engines tend to suffer more from oil starvation problems, particularly during high performance driving.
In addition to the standard issues associated with the non-traditional sump system, the flapper windows on the bottom of the engine are manufactured out of plastic, and can break off inside the sump and clog the oil pickup tube. This leads to oil starvation and complete engine failure. The solution is to remove the bottom sump and inspect the oil control windows (see Pelican Technical Article: Oil Pan Gasket Replacement / Deep Sump Installation), and replace them if they are missing or damaged. You can also add aftermarket stainless steel windows for added protection.
As mentioned previously in Pelican Technical Article: Oil Change, I do not care for Porsche's standard recommended oil change interval of 15,000 miles. The oil in engines tends to become contaminated with fuel and coolant, particularly as the cars age and seals and piston rings begin to wear. I generally like to run a thicker oil and change it every 3000 to 5000 miles. Keeping the oil fresh may help prevent some IMS bearing issues and generally prolong the life of your engine.
Connecting Rod Bolt Failures: The connecting rods that are used on the Boxster are forged out of steel and utilize what is known as a cracked-rod design. This means that the rods are forged and machined, and then broken along pre-set stress points. Then the bearings are installed and the rods are put back together again. This cracked-rod design is cheaper to manufacture, and the rod bolts don't need to have integrated "guide" pins as part of their design (like the rod bolts used on the older air-cooled engines).
Unfortunately, it would appear that the rod bolt diameter may be too small for the large loads that these engines place on the rods. A number of recent failures in some early high-mileage engines have hinted that the rod bolts are too small and may be a failure point for the connecting rod.
The failure occurs when the engine is consistently revved at the high end of its RPM range. The stock rod bolts are designed to stretch and permanently deform when tightened down to their final torque values. At RPMs of 6700 or higher, the rotating mass on the end of each rod (namely the piston and the mass of the rod itself) has a tendency to stretch the rod bolt further. Repeated stretching of the rod bolts causes them to deform and loosen up which can result in rod separation and complete engine failure.
Unfortunately, due to the cracked-rod design, the connecting rods cannot easily be rebuilt. The solution is to install aftermarket connecting rods that can accommodate larger, race proven fasteners like the ones available from ARP.
Variocam Solenoids: It's not uncommon for the variocam solenoids to fail on one side, which will result in a uneven, or lopey idle. Moisture can get into the mechanism causing it to corrode and eventually fail. The DME computer should be able to easily detect this failure and trigger a check engine light (CEL).
Paper Oil Filters: The oil filter system on the Boxster is a bit lame in my opinion. Using the stock paper filter can lead to a disintegration of the filter which can then clog the oil passages of the engine. Although this is a relatively rare problem, I have heard of it happening with cheaper brand oil filters. Stick to the good quality brands, and also consider upgrading to the LN Engineering screw-on oil filter upgrade (see Pelican Technical Article: Oil Change).
Air-Oil Separator Failures: The air-oil separator is an emissions device that draws vapors from the engine crankcase and then sends them back into the intake manifold. When this unit fails, the result is oil is sucked out of the engine and into the intake. While the air-oil separator will not cause immediate mechanical damage to your engine, it may make it smoke tremendously and / or run roughly (see Pelican Technical Article: Air / Oil Separator).
Oil Change Intervals: The best recommendation to any Boxster owner is to change their oil more often, say every 5,000 miles, as well as use a minimum 5w40 viscosity oil. On cars not equipped with Variocam Plus (2006 and earlier), use of a 15w50 or 20w50 provides a much higher film strength which will improve internal bearing life considerably.
Low Temperature Theromostat: Also useful is the LN Engineering low temperature thermostat (see Pelican Technical Article: Water Pump & Thermostat Replacement). This specially designed thermostat starts to opens at 160° F instead of 187° F for the factory unit. Keeping the oil cool is key to keeping it fresh and the lower operating temperatures also help to give you a bit more horsepower too.
This photo shows the flywheel end of an M96 motor. This particular motor is a 3.4 liter crate motor from Porsche that has been updated with the latest and greatest improvements from the factory. The intermediate shaft has the updated bolt (yellow arrow), but the issue of the intermediate shaft failures has still not been completely addressed in this redesign. Although these updated engines tend to suffer from fewer problems than the early ones, there is still a risk of IMS bearing failure. The rear main seal shown here is the updated and improved one that should not leak.
This is the infamous D-Chunk problem that happens sometimes on these motors. Occurring almost exclusively with the two cylinders in the middle, it is theorized that excess twisting and vibration causes cracks to occur in the cylinder walls. Found mostly on the 2.5 and the 3.4 engines, this problem is almost non-existent on the 3.2 liter engines because the 3.2 has thicker cylinder walls. The solution is to machine the case to accept cylinder liners (next photo).
Here is a fully repaired M96 engine with the LN Engineering Nickies liners installed. The case is prepared by machining out the old liner and completely removing the section that floats in the water jackets. Then, a Nikasil cylinder is press-fit into the case in its place. It's a clever solution to the irreplaceable case problem. The case itself must be a good rebuildable core and have no major issues (no major damage, no case porosity issues). In addition to replacing the liners with new and improved ones, the process allows you to increase the displacement of the engine at the same time. The 2.5 engines can be easily increased to 2.7 and the 3.4s can be pumped up to 3.6 liter displacement. There is even an option for 3.8 liter and beyond in current development.
Although it may not look like much, this crack is enough to cause a lot of problems. Cracks like these can cause oil / coolant to mix, resulting in contamination of the coolant and/or oil. Cylinder head cracks are common among water cooled cars, and can sometimes be repaired by grinding down the head and then rewelding it. Photo: Glenn
I was about to purchase my first porsche boxter and accidentally I've found your web site. Thank god I did or maybe not?
Just a quick question.
2006 987 boxter MY07- does it also have issues with the intermediate shaft bearing IMS bearing? Any other issues I should look out for?
Cars on Australia are 45% dearer than anywhere else in the world. So if you guys in states say replacement engine cost around $20k here would probably be double.
I'm looking at those cars. I think one is auto the others manual. Any advantages or disadvantages over the two gear boxes? Does auto means more problems or manual means expensive clutch replacements. I think there is one MY06. My favourite is for $43 silver with 57,000km.
I know you're probably laugh thinking this poor fucker is going to spend $40k on a boxter we wouldn't pay more than $20k in US. I also can't afford having to spend another $20k or $30k on a new engine.
I'm a middle class hard working separated middle life crisis 37yrs old guy who is going through marriage break up and needs a toy to enjoy or he will loose his sanity.
Comments: My 2001 boxster developed a "turn over/no start" problem. I would drive normal, park for 15 -30 min. and get it to turn over but not start. I waited for about an hour, tried again and it started normally? I developed a routine of letting it sit for at least 45- 60 min. and get a normal start. replaced the fuel pump relay with no fix. next thought fuel pump. Replaced it and again no fix. took it to my porsch dealer. It turned out to be a "intermittent fault in the crank sensor". replaced it, all is well now. that simple fix took a long time to isolate the fix and $800 later. Good work by Strongs Porsche and Kent livingston % the boys in Salt Lake Ciyy.
March 6, 2014
Comments: I have a '99 996 at just over 100K miles. It is starting to have problems starting after sitting for a few hours at 70F+ ambient temperature. The car starts right away at lower temperatures or after sitting for a short time, but cranks for 10 - 15 seconds after sitting at higher ambient temps before starting. Looking for ideas on how to diagnose or resolve as summer is approaching....
March 4, 2014
Comments: I have a 2008 Boxster S with a surging problem. Staring at around 1800 rpm, up to about 2200 rpm the engine will surge about 200 rpm while accelerating. it does not happen outside this range, but it is consistent and throughout that rpm range. The car now has 65K and it has been becoming more pronounced. The dealer reports "cannot duplicate' and there are no reported fault codes. It is my daily driver and I just love the car!
February 22, 2014
Followup from the Pelican Staff: The surge can be from a fuel delivery issue, vacuum leak or air intake issue. If the problem cannot be duplicated in the shop, you may have to wait until it becomes more pronounced. Intermittent issues are hard to diagnose, and the lack of fault codes doesn't help. - Nick at Pelican Parts
Comments: It is so crazy to think that a modern Porsche Boxster would have so many serious issues. Engine replacing? Best sugestion for any Future Boxster owner in my book would be, stay away and invest in a well maintained daily or weekly driven 81-83 Porsche 911sc or any 930 at that and you will have many many years of headache free memories!!! I have seen well over 200k miles on early never rebuilt Porsche 911's satisfying their owners every time they drive ! Newer modern not always means better ! Anyways just my opinion, don't kill me now ! LOL ! Porsche Passion! Living it, Love it! Is it in you ? Porsche Kid
January 31, 2014
Followup from the Pelican Staff: The 911SC I bought for the 101 Projects book I wrote had seven broken head studs. Every engine since about 1968 or so (with the layshaft problems) has had issues. 911SCs also suffered from chain tensioner failures too. So, each engine did indeed have it's own problems. The Boxster is no different, and it's fixable just like 911SC head studs, and chain tensioner issues. - Wayne at Pelican Parts
Comments: I am looking at purchasing a 1997 Porsche Boxster with 32,000 miles for $9,700.00. Can you tell me what questions I should ask the owner and what I need to look for so I can make an educated decision? Any help would be greatly appreciated.
January 30, 2014
Followup from the Pelican Staff: Browse our forums and check out the common issues. Or have a Porsche repair shop perform a PPI. - Nick at Pelican Parts
Comments: Boxster 2.7l 2001, Cylinder Head Removal - does it require dropping the engine out of the car, or can I do it in situ ?
January 27, 2014
Followup from the Pelican Staff: I would suggest dropping the engine. I have not tried to do it with the engine installed. - Nick at Pelican Parts
Comments: thank you for your service, it is great to have your support!
January 17, 2014
Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
Comments: If you purchase a catback exhaust which claims a grain of 10 hp and also a header with sports cats which also claim a grain of 10 hp, would the hp total 20 hp or less than, or more?
January 17, 2014
Followup from the Pelican Staff: The claims would put you at 20hp more. - Nick at Pelican Parts
Comments: have replaced battery 3x in past 14 months. 2003 boxster s with 27500 miles. Purchased from Porsche of Omaha. After being checked out was told that battery drain when parked and locked not uncommon and should keep on battery tender!!
January 15, 2014
Followup from the Pelican Staff: Either find the source or the parasitic draw, or use the battery tender.
- Nick at Pelican Parts
Comments: I was about to pull the trigger on a 99 Boxster with 98k miles on it. I owned two 944s over the years put over 200K on both and found them to be pretty much reliable as long as you keep up the belts and CCT but after seeing all the failures I'm REALLY feeling lost here. Is this a 50/50 chance of melt down or a 1 out of every 25 thing?
January 8, 2014
Followup from the Pelican Staff: Hard to say. Have a PPI performed by a Porsche mechanic and ask for the service records. If the major repairs (issues) have been dealt with, the vehicle should be fine. if they haven't been dealt with, be prepared for them. - Nick at Pelican Parts
Comments: I am looking at buying a 1-owner 2000 Boxster S with 32,800 miles. What should I look for, be concerned with or ask about with this car?
January 4, 2014
Followup from the Pelican Staff: I would ask to see the service records. Has the IMS been replaced? How about the coolant pump and AOS? A PPI is your best bet. - Nick at Pelican Parts
Comments: I had the gear cable of my 987 boxster s 2007 come off three times. The dealer put it back on two times. It came off again for the third time,the dealer claims I need new cables. Is this an on going problem with the boxster? Are these cables known to be defective. I do not feel safe with this situation,has this been an ongoing issue for the 987. Also, I am told the cost to replace the cables is around 1200. Do you know where I can purchase these cables and instruction and how to do it?
December 26, 2013
Followup from the Pelican Staff: Not a major issue, but if it keeps coming off, the cable end is likely worn. - Nick at Pelican Parts
Comments: does flashing a 987 boxster have a down side,harmful to the engine
December 23, 2013
Followup from the Pelican Staff: Any performance modification will add stress to your engine and drivetrain. However it is done frequently without bad results. It really depends on how you drive, maintain and treat the vehicle. - Nick at Pelican Parts
Comments: Well it seems even years of babying my beloved 2006 Boxster S it wants to fail me. Local indy Porsche shop says my car has symptoms of RMS or IMS going bad. Anyone know what are round about estimates for parts/labor to replace above mentioned items? It's gut wrenching knowing that this may cost me...an arm, leg, reproductive organ, kidney and a lung to replace!@#$
December 17, 2013
Followup from the Pelican Staff: The price for this repair varies greatly on what you have to repair. IMS failures vary. I would get an estimate, then call around to few Porsche specialists and see what they have to say. - Nick at Pelican Parts
Comments: Hi Wayne I have been a g standing owne, 15 years 924/944 and 12 with 911s. I bought a 2000 Boxster S 68k with a noisey top end with oil burning issue. I have stripped out the left nk cams and all of the followers have collapsed. I have submerged them in oil ut they will not prime. The oil pump seems to work when turned submerged in oil and the plugs in the end of the cams are present. All looks clean with no wear or debree. The car was serviced 2 days before the failure. Before I replace the followers is there anything else I should check. There is a fair bit of oil between the engine/gearbox area all around but the torque converter looks dry both sides from the little I can see. I have your book and the Bently manual and good mechanican knowledge and getting cold at 58 on my Lambretta in December...Cheers and good work my friend.
December 4, 2013
Followup from the Pelican Staff: Have you checked oil pressure? - Nick at Pelican Parts
Comments: I have a 2003 boxter S and suffered a catastrophic engine failure under warranty with the cam failure the engine was replaced and the second engine also failed at 94K miles porsche North America. Said the car has too many miles on it at 143K but the second engine was under 100,000 miles. Any thing I can do besides switching to a mercedes??
November 12, 2013
Followup from the Pelican Staff: You can have your engine rebuilt or a used engine installed. This would be my suggestion. You know the car well and if maintained well it will last for some time. - Nick at Pelican Parts
Comments: I have owned a 2001 Boxster S since 2002 - bought it from a Porsche dealer. After doing a major serviceabout $1200 at the dealer, 2 months out of warranty, the engine is dead. Dealer told me "tough luck" but it's out of warranty. I recently heard that Porsche had been replacing some 3.2L motors that were out of warranty, but that program has stopped like my motor. Was I eligible for that program and just didn't get that info from my dealer???
November 10, 2013
Followup from the Pelican Staff: I am not sure what is covered on your vehicle. My suggestion is to call a different Porsche dealer, ask then to run your VIN and see what the warranty is or was on the vehicle. If you are close to the mileage or time, you may be able to get them to honor it. - Nick at Pelican Parts
Comments: Can a 911 motor be put into a 2001 Boxster S chassis??
November 7, 2013
Followup from the Pelican Staff: Yes, you may will have to swap components from your engine to the new one. Of course how easy the job is depends on if you use the same year and engine code.- Nick at Pelican Parts
Comments: How difficult would it be to put a 911 motor in a Boxster...my 3.2L Boxster motor is cooked!
November 6, 2013
Followup from the Pelican Staff: Depending on the year, it wouldn't be that bad. The engine is similar. You would need to swap your components and transmission over. Just look for the same engine code when shopping. - Nick at Pelican Parts
Comments: Hello I have a 1999 Boxster with 37K miles. It has worked great until we got P1324 Camshaft position with respect to crackshaft bank 2 exceeds limit value, P1387 camshaft position sensor bank 2 short to ground and P0304, P0305, P0306 which are misfires on all cylinders in that bank. I now have a rough idle due to the misfires. I have replaced the spark plugs and coils for that side. According to my durametric my timing is off on that side by 25 degrees. Is it possible that a bad solenoid could cause that or could it be the variocam tensioner for that side. I have access to a used engine that i had from another boxster so I can get the veriocam and sensor from that one but I wanted some opinions before I tinker further. Thanks, David A.
November 4, 2013
Followup from the Pelican Staff: An actuator could fail, but I see more mechanical timing issues. The misfire also makes me think it is a mechanical issue. I would check mechanical engine timing. Use camshaft locking tools to lock the engine down and see if it is properly timed. - Nick at Pelican Parts
Comments: I just bought from a local independent dealer a 2004 Boxster 2.7L 5-spd w/ ~70,000 mi, confirmed the IMS had been retrofitted, and had a new clutch. Car leaked oil from Day 1, stalled when coming to a stop with A/C on, and had unusual engine noise after an hour of driving. In the shop and out the first two months no charge from dealer but continuing problems until finally the big one: cylinder bearing gave way and spun the crankshaft, damaging it irrevocably. They tried to get it machined, no luck. So choices are: 1- Demand my money, or most of it, back no warranty; 2- Go with their recommendation to put another used motor in; or 3- Have them replace the crankshaft, seals, oil pump, etc. with new parts and put my motor back in. They say the rest of the motor is perfect and they have cleaned it up completely. They are balking on the new crankshaft because it is so expensive. I am leaning towards Option #3 because I am not confident that another motor out of a crashed car will not come with major problems of its own, and I'll be at risk. The dealer has mentioned using parts from Pelican. What is your "impartial" recommendation?
October 15, 2013
Followup from the Pelican Staff: This is a tough call. When there is a major bearing failure the engine oil passages can be filled with metal debris. This can lead to future failures if the engine is not completely torn down and cleaned. I think the rebuild or a used engine is a good choice. That is if they perform the rebuild correctly. If you are not confident in their ability, ask then if they would pay for a shop you trust and have a relationship with to perform the repair. - Nick at Pelican Parts
Comments: I NEED HELP I have a 2000 boxster 2.7L M96 5 chain motor with 30,000 miles on it. Recently the car began to idle rough and the Check engine Light CEL came on. The OBDII code was P1341 related to vario camshaft adjuster. Pulling off the cam cover, and removing Bank 1 camshafts we found that the cam-adjuster plunger was stuck which is probably why the car was idling rough. The larger concern was that we noticed that one bearing surface on the intake camshaft on cylinder 3 near the chains was very rough and worn. All bearing surfaces were very clean and smooth exempt this one see picture. Q1 - Anyone know what would have caused this? Q2 Suggestions on how to fix this bearing surface on a the head and b the camshaft bearing cap? Q3 - How to prevent this from happening again?
This is a weird one and need any HELP / suggestions you may have!!!!
October 7, 2013
Followup from the Pelican Staff: This is from an oiling problem or debris in the engine oil. I would inspect the oil filter element for metal or debris. This could be from a failing bearing in the engine, putting small metal pieces in the engine oil. Looks like you will need a new cap and camshaft at the minimum. Hopefully you caught it early enough. - Nick at Pelican Parts
Comments: I own a 1997 boxster with 30,000 miles on it i am the second owner i change every 3000 miles . Car has never had any mechanical issue only regular maintenance.
I want to keep the car for a long time. What do you rcommend i do mechanically to the engine to prevent know failures .
Also what is aproximate cost of these mods .
Ims bearing etc Does pelican sell kits to strenghten these weeknesses.
If so what are the part numbers and price.
October 6, 2013
Followup from the Pelican Staff: I would replace the rear main seal and the IMS bearing if you plan to keep the vehicle. Those two are the major issues you want to deal with before they fail. Other than that, keep up on your maintenance and the vehicle should be OK.
Give our parts specialists a call at 1-888-280-7799. They can help you find the right parts. - Nick at Pelican Parts
Comments: I have a 2001 boxster s. When the car is warmed up and idling I hear a rattling noise when I am outside it. The noise goes away if I push the clutch in. What do you think. This only happens when it is really warmed up ThNks
October 6, 2013
Followup from the Pelican Staff: This could be a faulty clutch disc spring. When the clutch pedal is pressed, the disc is disengaged, stopping the noise. I would replace the clutch and all the bearings, of course inspect it first to be sure you need these parts. - Nick at Pelican Parts
Comments: Recently purchased a dealer maintained 2000 Boxster S with 104k mile. Dealer PPI revealed some oil leaks- listed as RMS and cam. After purchase, a good indep mech replaced RMS, IMS bearing and other seals. Still leaked. Back to dealer who said RMS, second indep mech said RMS. Original mech put a camera under car during test drive, suspected bad IMS bearing seal. Redid the seal, still leaked. Finally indep mech found leak in the seam where the two parts of the motor ase are joined. Leak is relatively min. Can I live with this?
September 24, 2013
Followup from the Pelican Staff: I would have the mechanic check the crankcase alignment. There is a gauge to measure the RMS seal bore to see if the crankcase is properly aligned. - Nick at Pelican Parts
Comments: I have a 2005 Boxster and I have had to get an air mass sensor MAF sensor replaced by the dealership, which I paid for. Would this be considered part of the IMS related damage class action lawsuit and I can get reimbursement?
September 24, 2013
Followup from the Pelican Staff: I'm not familiar with the suit or outcome. This site has all the details of the lawsuit and settlement. http://www.imsporschesettlement.com / - Nick at Pelican Parts
Comments: I am looking at a 2007 Porsche Cayman S , this car has 75,600 miles on it. I am not a mechanic by any means. This car would be my daily driver and I would like to get at least 50,000 more miles out of the vehicle with just normal maintence,is this possiable, do not plan on racing it or hot rodding it either. Or should I just find some other brand car? Thanks for your advice.
September 22, 2013
Followup from the Pelican Staff: You can definitely do that. Before you buy it, have a Porsche work shop perform a pre-purchase inspection on it. This will help to uncover any hidden issues, if there are any.
With proper maintenance the vehicle will last quite a while. - Nick at Pelican Parts
Comments: Nick,thanks for taking the time. What are the main concerns-shaft bearings etc. to watch out for on the 2010 boxter S ? I will change my oil every 5,000 mi. Here is the tough one will the 07 front license plate bracket boxter work on the 090 and 10 boxter, again thanks for you knowledge and expertise. Derk
September 18, 2013
Followup from the Pelican Staff: 2010 S models have the new style engine, direct injection. Not sure they have been in circulation long enough for us to have reliable failure data. As for now they are proving to be good engines. Just keep up on your maintenance. - Nick at Pelican Parts
The Flying Pelican
Comments: Your information is quite valuable. Very interesting and informative. My 03 boxster s at 70000 miles had a clutch ,March 2013, replaced by the previous owner and the dealer will not tell me if they replaced the IMF bearing at that time. Do you think it would have been inspected and changed to a new one if needed. This was a reputable Porsche dealer. Thanks for any input, jim Guarino ft lauderdale, florida
September 17, 2013
Followup from the Pelican Staff: It's impossible for me to know. However, you can contact the dealer with the VIN of the vehicle and ask what was replaced during that service. They will be able to tell you. - Nick at Pelican Parts
Comments: Understand the drain time on oil change for 2010 boxter 3.4 is very lengthty even when oil is hot. Looking for a average time? Thanks, Derk
September 17, 2013
Followup from the Pelican Staff: Maybe 10 minutes max. I have never had to wait even that long. - Nick at Pelican Parts
Comments: Just purchased a 2010 boxter S with 6000 mi. Is there any recommendations besides changing oil now and not waiting till 10 or 12 thousand. Plan on running 0w 40w Mobile one? Just looking for suggestions from knowledgeable group of enthusist. What to look out for on this relative recent model/ Thanks, Derk
September 17, 2013
Followup from the Pelican Staff: I would replace your engine oil every 5,000 miles. That is the longest I go on any of my vehicles. - Nick at Pelican Parts
Comments: Great site. Looking at buying a 2006 Boxster base model with 43,000 miles on it. Did a search on any issues which is how I found this site. I see ton's of issues with the 2005 and older models here and have some hope that the 2006 is much better with the revised bearing. I know the 2009 design is much better but the cost is twice as much for the vehicle. Thoughts on the M97 engine reliability in the 2006 model?
September 14, 2013
Followup from the Pelican Staff: M97 engines have similar issues, the IMS is one of them. The later engines have not been in circulation as long, so the bearing can seem ore reliable. Have a pre-purchase inspection performed on the vehicle, this is a good way to figure out which to buy. - Nick at Pelican Parts
Comments: I recently took my 2003 Boxster into the dealer for an oil change. The team at Beverly Hills Porsche performed a thorough inspection and discovered that there was "seepage" coming from the area where the transmission connects to the engine. Could this mean that the intermediate shaft bearing is beginning to fail? The car has not been driven much over the last 3 years. It has 52,000 original miles.
September 13, 2013
Followup from the Pelican Staff: This could be the IMS bearing or the rear main seal. - Nick at Pelican Parts
Comments: What is my well maintained 986 had a catastrophic engine failure, probably cylinder head or block cracked still investigating... Did you hear about Porsche taking care of that kind of situations?
September 13, 2013
Followup from the Pelican Staff: You will have to check with your local Porsche dealer to see if the failure is covered. Call then and have them check your VIN and explain the issue to them. - Nick at Pelican Parts
Comments: I have a 98' boxster that I recently purchased. The guy I bought it from owned it for about a year and spent that time working on it as a project, not really driving it. He removed the engine to clean it car is pristine and he did some upgrades. Stainless steel headers with cat back hi performance stainless low flow exhaust and a cold air intake. Currently, the check engine light is on and I have codes for all the oxygen sensors and Idle air control valve. Is it likely all the Oxygen sensors went at the same time? As far as the idle, it seems like it is working fine.. no fluctuation at all. What could cause all these codes to be thrown if its not actually the sensors? I should add that the check engine light was on when I purchased the car the other day. I purchased as is.
September 13, 2013
Followup from the Pelican Staff: How many oxygen sensors have codes? I would check operation of each sensor. If they cannot respond to changes in the exhaust gas content then they are faulty. There may be an air leak causing the idle valve fault. If the o2s are switching, this could also be part of the problem with them, - Nick at Pelican Parts
Comments: does 2013 have plastik liners?
September 12, 2013
Followup from the Pelican Staff: Not sure what you are asking. - Nick at Pelican Parts
Comments: I am looking at a 2000 boxster with 90,000 mi was service well. Last service was 2.5 yrs ago at 80,000 not driven much in the last 9 mo. I am also considering a 1999 with 103,000 mi owner says they had it service but no records. Both are visually excellent. The 1999 is $2,000 less. Which one would you recommend ?
September 8, 2013
Followup from the Pelican Staff: I would lean towards the 2000. However, I suggest having a pre-purchase inspection perfromed on both vehicles. A mechanic can help to identify any problems you might not be able to see. - Nick at Pelican Parts
Comments: Hi I have a 98 boxster, i had an accident about a year ago. The front right was hit, and the radiator and wishbone for the wheel were replaced. The A/C doesn't work nor the horn. Now the main issue is that it idle extremely rough. And will not accelerate at all. When left in neutral while parked, it will not rev past 3,000 rpm and sound like there is a bickfire. The car is at the shop and the throttle body was replaced, the issue remains. The fuel was checked, pump is working fine. Plz help me with suggestions.
September 7, 2013
Followup from the Pelican Staff: I would start by checking the DME for fault codes. If the system is not working properly, a fault code will be set. It may indicate which cylinder is giving you an issue. If the engine is backfiring, it could be a mechanical timing issue. - Nick at Pelican Parts
Comments: Who should I contact at Porsche about blown engine at 80K miles with car that has been maintained to Porsche maintenance standards?
September 7, 2013
Followup from the Pelican Staff: I would start with your local Porsche dealer. - Nick at Pelican Parts
Comments: I have a 2006 Boxster with a little over 80,000 miles. I have had zero problems with it since I bought it three years ago. I have put about 45,000 miles on it with normal driving. I have had regular service with a shop I trust tune ups oil changes brakes etc but I just had the spark plugs and the air filter changed this week and the very next morning, driving down the freeway at normal speed, the engine started billowing smoke and oil level dropped. I stopped and had the car towed back to service shop and was told that thee was oil in the spark plug hole which had led to engine failure. The question I have is what could have happened? Is it just a coincidence that I just had the car serviced the day before? Any advice or feedback is appreciated.
September 5, 2013
Followup from the Pelican Staff: Your Air oil separator may have failed. have the shop look into this. Is can fill the intake with oil when it fails. - Nick at Pelican Parts
Comments: I am thinking about buying a 99 996. The car has 100,000 miles on it and looks in good shape. Runs wellwith no loss of power or hesitation and has new clutch. When I inspected the coolant expansion tank the back end of the cap had a thick tanish substance on it and the coolant looked murky and discolored not red or green. Didn't look muddy brown either. Dipstick was normal. Inside of oil cap hap slight witish discoloration with slight amount of water but engine was warm to the touch. My concern is intermix problem what are your thoughts. No white or black exaust.
August 29, 2013
Followup from the Pelican Staff: The coolant tanks tend to look like that. If you suspect intermix, I would have the cooling system tested, don't take a chance, these engines are expensive. have a pre-purchase inspection performed by a Porsche work shop, you won't regret it. - Nick at Pelican Parts
Comments: I would like to nominate valve springs to this list of engine problems. I had one break. I have a 2000 Boxster S with about 110K miles. I saw some chatter about them online, they may be the up-and-coming problem. Luckily it didn't do much damage, the valve stayed in place. The problem was the 30 hours of work to change it. I am putting in the Pelican IMS bearing while doing all this work. For the records, the old double bearing wasn't falling apart, but it also wasn't perfectly smooth.
August 27, 2013
Followup from the Pelican Staff: I haven't heard too many valve springs breaking, but we appreciate the new info. Replacing an IMS when it is not faulty is the best time to do it, before it fails and causes engine damage. - Nick at Pelican Parts
Comments: Hi: Never owned a Porsche before. Been looking at Boxsters as an entry. I've been looking for a project-like car. Found a 2002 Boxster. It has 78500 miles on it - but owner says it... "needs a new engine" don't know why yet. Owner is asking $5000 for it. Seem high. What do you think is a reasonable price for this. If everything else looks good. I would try to do all the work myself. I'm experienced with old VWs and motorcycles. Thanks!
August 27, 2013
Followup from the Pelican Staff: Depends on the condition of the body. Might be worth having a local Porsche mechanic look at it and give you solid adivce on the specific vehicle. - Nick at Pelican Parts
Comments: I have a 1999 Boxster Canada Model and the warning light "!" came on. The manual doesn't show that warning light and I can't seem to find it online. Can anybody tell me what has to be fixed?
August 25, 2013
Followup from the Pelican Staff: This is to warn you there are other fault messages. Check the driver information screen. There will be another fault message displyed. If not other light is ON, scan the vehicle for faults. - Nick at Pelican Parts
Comments: I bought a 2005 Boxster with 43K kl. The engine failed during our vacation and I am bringing the car home to Canada, any suggestions?
August 25, 2013
Followup from the Pelican Staff: Depending on what failed, there are many options. Everything from repairing the broken part, an engine rebuild to a replacement engine. FIrst you will have to figure out how bad the failure is. - Nick at Pelican Parts
Comments: I just bought a 2000 Boxster and I have found a leak of a clear fluid oil type from the passenger side rear, It looks like it is coming from the axel, any idea what it is? Thank you
August 21, 2013
Followup from the Pelican Staff: Clear? Could be engine or gearbox if it is clean fluid. I would jack your vehicle and try to locate the source of the fluid leak. Then it will be much easier to help you descide what to replace. - Nick at Pelican Parts
Comments: i have a 1999 boxter 2.5 and love it. just recently i had the water gauge goes high as 200 degrees so i stop driving it and immediately took it to a shop. No water leaks but the water was low in tank. They replaced the thermastat and cap on tank and vaccuumed the line. It always ran at 180 degree and now is 190 and light is flashing. The fan is running strong. What could be the problem for i do not want it running at 190. Help
August 16, 2013
Followup from the Pelican Staff: You could have a failing water pump or debris restricting flow. I would inspect the thermostat and check the cooling system for exhaust gases, just to be sure. - Nick at Pelican Parts
Comments: Today I was driving home when my ABS light flashed on then off again. When I reached home I turned the engine off. Then I turns the key to see if the abs light came on but it never. But then the dash said faulty airbag. So I turned the car off again and then turned the key again and all the dash lights flashed. Then the alarm.went off. It was like the car was possessed! I got out unlocked and locked the car and have not touched it since. I did notice the car was revving slightly higher and the temp was slightly higher than normal.
August 12, 2013
Followup from the Pelican Staff: Multiple warning lights coming on could be a charging system issue. I would scan the vehicle using a Porsche scan tool. What ever faults are stored will help you diagnose the problem. - Nick at Pelican Parts
Comments: Hi. boxster s 2001 problem
My oil light a goes on at the same time that the battery light. But this happens only after 20 minutes driving And if i stop the car and turn it on again the lights are not on anymore. Im not sure if its oil pressure sender or electrical problem.
August 1, 2013
Followup from the Pelican Staff: Do not take a chance with an oil light.I would check engien oil pressure immediately. Also, perform a charging system test to check if the alternator is charing. - Nick at Pelican Parts
Comments: Hello - I'm considering a new Boxster, 2013 or 2014, base model with 2.7L engine, manual trans. I will keep this car a long time and likely put 200K+ miles on it. Do the current engines still suffer any of the issues you describe, or have these been engineered out? Any other concerns? Thank you
August 1, 2013
Followup from the Pelican Staff: The later engine are quite different (duirect-injection) and it is hard to say what if any problems will develop. I would go for it and enjoy the car, just maintain it and I'm sure it will last quite a while.- Nick at Pelican Parts
Comments: by the way while replacing clutch we foud a coolant leak from oil cooler which we replaced too.
July 25, 2013
Followup from the Pelican Staff: Thanks for the additional info. - Nick at Pelican Parts
i replaced a clutch on a 1999 carrera with a 3.4 engine.atarted the engine for less than a minute to make sure clutch is ok then turned engine off.finalized the job and put all covers back then started again,at this time engine ran rough and was blowing white smoke from tail pipe.combustion leak test showed HC in cooling system.car was never tested befor and it was driven into shop.customer towed car away to another shop were they found that block and head are cracked.customer is holding me responseble.question is was there anything i could have done to cause that damage? please helpwe are going to court.
July 25, 2013
Followup from the Pelican Staff: You do not want to look for HC when testing a cooling system for a head gasket issue, you want to check for Co2.
I cannot offer any advice as to what may have happened as I was not involved in the repair. If you are confident in your repair precedure, just stand by it and hopefully it will work out. - Nick at Pelican Parts
Comments: Hi, I have built a 3.2 boxster 96/21 for racing in the UK.
The engine is standard except for a deep sump and accumulator. First time out after 5 laps it started to rattle and the oil light flickered, my first thoughst were knackered engine crank bearings. Having run the car again at home all sounds well with no rattles but the oil light still flickers at low revs. The rattle didn't sound heavy enough to be big end or main bearings but having taken the sump off there is light residue of something very wrong, but the small particals are bright gold or brass not what I would expect from white metal bearings. Before I start on my first Porsche engine strip and rebuild any ideas on what the problem may be. Cheers
Very usfull articals by the way
July 17, 2013
Followup from the Pelican Staff: Sounds like yopur oil pressure is low, I would check it with a gauge.
I have seen metal debris in oil pans and oil filters look gold colored but be from bearings and other parts. Check the debris with a magnet. It could be from your IMS bearing or other engine bearings. I would cut the oil filter and inspect it for debris also.
if there is engine noise, the damage has been done. Hopefully you caught it early enough to minimize damage. - Nick at Pelican Parts
Comments: I have a 99 boxster with 125k miles on it. Currently I'm having an issue where the car will run fine for about 20 min. then die out on me. If I wait about an hour the car will start right back up and drive no problem for about anothe r20 minutes or so. No CEL or anything, I've already replaced the fuel pump but same results. What else should I look at?
July 16, 2013
Followup from the Pelican Staff: Sounds to me like you have a bad crank sensor failing when it gets hot. - Nick at Pelican Parts
Force Recon USMC
Comments: My 2003 Boxster just had IMS-failure. I didn't have APCO coverage,so I can only recover 25% of my repair cost. That's if I take the class action law suit. My plan is to do what has worked for me in the past with these put the customer last companies. I picketed Gateway computers, and Allstate Insurance and I won!
Just make good signs and be truthful
July 15, 2013
Followup from the Pelican Staff: Great to hear,...I think. - Nick at Pelican Parts
Comments: I hope you can provide some guidance? I have available to purchase an early 05 Boxster base 5 speed manual with 14,700 miles and clean title. The owner purchased it in May 05 and did the full dealer 20,000 mile service at 6400 miles in 2008 and did an oil change in Feb 2012 at approx. 12,650. So the original owner did two oil changes in 8 years and did a total of 14,700 miles. Should I walk away or does the low mileage mitigate the lack of oil changes? If purchased,price is $21500 should I do the IMS upgrade immediately? Your input is greatly appreciated.
July 8, 2013
Followup from the Pelican Staff: If they used synthetic oil you're okay and yes do the IMS upgrade immediately - Nick at Pelican Parts
Comments: Great website and resource. Thank you!
Am considering a Auto transmission 1999-2001 Boxster or Boxster S in the $7000-10000 range. I am comfortable working on cars Miata, Audi A6, VW Passat, Subaru WRX, Mini Cooper from exhaust swaps, sway bars, brakes, radiators, water pumps, and timing belts.
What should I look for inside and outside when inspecting a used Boxster in this range? I will consider a mechanic inspection, as well, but I'd like to know what to look for during and initial drive and inspection.
Let's also assume the seller only has a Carfax report and minimal service records.
July 5, 2013
Followup from the Pelican Staff: Check our tech article list for Boxtser vehicles, this will give you an idea of the common issues. The indicator is a well maintained vehicle. A vehicle someone has cared about and cared for will likely need less work if any. My suggestion is to pay for a vehicle PPI. - Nick at Pelican Parts
Comments: Hi I have a 2001 boxster s shes stood for some times, an reasantly the brakes have gone rock hard? It stops but you've really got to push? The servo is acting ok , pump the peadel an then start peadle sinks slightly so in my mind that's how it should be! Any thorts would be fantastic!
June 30, 2013
Followup from the Pelican Staff: If the pedal is rock hard, the brake booster could be faulty, or you could have insufficient vacuum to the booster. - Nick at Pelican Parts
Comments: I recently bought a 2005 Boxster with 21K miles on it. I noticed that at highway speeds there is a mechanical whine that goes away when I depress the clutch and let the car coast at the same speed. The whine is at a constant pitch even when the speed or RPM changes, just the volume seems to increase when the car warms up more. At low speed I cannot hear it. Any ideas if this could be a bearing starting to fail?
June 28, 2013
Followup from the Pelican Staff: This noise could be a bearing. The way you describe it going away when you press the clutch leads me to believe it is a clutch bearing. It sounds to me like the throwout bearing is the culprit. The pilot bearing is not spinning when the clutch is engaged, (clutch pedal up) so it is unlikely the pilot bearing is making the noise. - Nick at Pelican Parts
Comments: I own a 996 tiptronic 1998 with the 3.4 engine with 85.000 miles. I hear a tapping noise when the engine is hot and it goes away when reving the car even slightly or engaging the tiptronic in "R" or "D". Sometimes the noise is heard on and off at random. The oil pressure remains the same. The Porsche dealer is unable to give a solution so I come up with one. When I engage a gear in the tiptronic it alters the load or weight/mass of the crankshaft and increases its demping effect. The car is 15 years old and as the chains wear and the sprockets wear eventually there could be enough slack to allow the snatch to sound like a tapping noise. Am I right and could this noise merely a snatch noise slowly creeping up on older engines and harmless? The noise is being heard for years while the car always drives perfectly and is in a well maintained condition.
June 24, 2013
Followup from the Pelican Staff: I would think not. If the chains wore or stretched slightly, the chain tensioners would pick up the slack. Therefore negating the noise. If you have constant noise, you may have a worn timing chain guide or other component. I would suggest putting an oil pressure gauge on the engine and confirming it is good. - Nick at Pelican Parts
Comments: I have had my 06 Cayman for the past five years and have enjoyed it very much. 34,000 miles, properly maintained and driven. No track time. It is now burning a quart of oil ever 1000 miles. Only smoke visible is on startup. I was thinking th aos might be failing, but it idles fine and has suction where oil is added. Hoping I don"t have a a scratched cylinder. I would appreciate your thoughts. Dealer said oil consumption is within guidelines. Thanks
June 13, 2013
Followup from the Pelican Staff: Leaking valve stem seals usually lead to smoke on start up but goes away when warming up. A little oil usage is normal with these engines. I hope that helps - Nick at Pelican Parts
Comments: Hi - I would really appreciate your help. I have a 2003 C4S with 80,000 miles, and it is great. However one problem that has recently started involves getting past 4000 RPM in any gear. Once you hit this 4000 RPM, there was a judder, like a mifuel, and the revs became jumpy and indeed stopped accelerating. Coils changed, same thing happens. Fault codes said crankshaft sensor and cylinder 2 electrical short to ground. Sensors replaced, plugs replaced - all running great - for 1 month. Now starting to happen again; yesterday it "hesitated" at around 4000 RPM; no reaction, then later on same again then CEL is illuminated and power is lost. Turn on / off and drives fine but with CEL still on. Dealer said no error codes logged. Suggestions of variocam actuators? any other ideas? Thanks Jason
June 7, 2013
Followup from the Pelican Staff: if the check engine light is On, there will be fault codes stored.
I would start by checking the DME for fault codes. If the system is not working properly, a fault code will be set. This will be your best bet when diagnosing.
The electrical circuit codes you had in the past may point you to the root of the problem. The wiring harness may be damaged or shorted.- Nick at Pelican Parts
I'd had 08' Cayman S from new and 65K KM with it..Last year my engine had damaged due to main bearing fault.after repaired them damaged again last week.
I'd find out water leak at below water pump near black case..cause fault from here??
My question is after repaired engine and started had P0304,P0305,P0302 misfire..rough idle I mention.
Check already for coils,spark plugs,wire plugs had 12V,
Also Unburned fuel can be found after start.
Need help for result my engine fault plz.
June 5, 2013
Followup from the Pelican Staff: The coolant leak could be a hose or water pump. I would pressure test the cooling system to locate the source of the leak.
The misfire codes need to be addressed also. Check spark, injector pulse and fuel delivery at cylinders with codes. If all is OK, check cylinder compression.
- Nick at Pelican Parts
Comments: I am about to Replace the waterpump on My 2001 Boxter .What , or how,do I bleed the system? Thanks Joseph
Comments: I have 1999 Boxster 2.5 with pulled, yes I said PULLED head studs. Sounds like a air cooled 2.7???
Head bolt threads are in a @ 8" deep hole. Anyone herd of this one and possibly fix? Other then replacing the case.
Mahalo and Aloha, DS
May 24, 2013
Followup from the Pelican Staff: Hi there. I'd bet you a steak dinner it's not "pulled head studs". Studs just don't pull out of aluminum - not even on the 911 motors - they snap before that happens... - Wayne at Pelican Parts
Comments: I have a 1998 boxster I just rebuilt the engine and the water pump is turning backwards and the engine is over heating. any suggestions on where I went wrong/
May 21, 2013
Followup from the Pelican Staff: The only way I could imagine this happening is if the drive belt is misrouted or the water pump is defective. - Nick at Pelican Parts
Comments: what is causing my 98 boxster 2.5 liter to idle rough an hesitate below 2000 rpm it has 122000 miles on it an it just started acting up like it was misfiring any solutions
May 12, 2013
Followup from the Pelican Staff: If the problem is only present at low RPM, it could be a vacuum leak or slight engine misfire.
I would start by checking the DME for fault codes. If the system is not working properly, a fault code will be set. This will be your best bet when diagnosing.
If there are no fault codes, check each cylinder for spark, fuel and compression. - Nick at Pelican Parts
Comments: I've had a 1997 Boxster for 4 years now and would like to dispell some of the "myths" surrounding Porsches. The bottom line to Porsche longevity is strict maintenance. Also 90% of the time, as with any car, catastrophic failure will present warning signs. Porsches are not for the mechanically incompetent. Need proof? Look where the engine is. All that being said, there is no car I've driven that remotely compared to driving a Porsche.
May 6, 2013
Followup from the Pelican Staff: Thanks for the additional information. We appreciate it. - Nick at Pelican Parts
Comments: I just bought a 2004 996 with 50 K miles. I am concerned about the I M S problem. What options do I have besides the L N Eng. retrofit kit. I have a good mechanic but I need the correct parts.
April 26, 2013
Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need. - Nick at Pelican Parts
Thanks for the quick reply this morning. Regarding the article on Boxster S transmissions and my 2nd not working please send to my email in edit section.. Greatly appreciate your help!
April 23, 2013
Followup from the Pelican Staff: Done! - Wayne at Pelican Parts
Comments: Wayne, Hoping you can provide guidance. I purchased a 2004 Boxster S new and currently have 24K on it. Love it and plan on keeping it despite the lack of power! Last year prior to storage, I was beating her up and missed a down shift. I no longer have second grinds. First works well but is no longer fluid to shift into. 3,4,5,6 are still smooth like nothing happened. It is a 6 speed manual. I have limited knowledge of transmissions and would not know if I'm being taken to the cleaners. Can you give me an idea of what components should be looked at before a complete rebuild is needed? Appreciate your forum and the help. --Embarrassed
April 23, 2013
Followup from the Pelican Staff: It might be the detent in the transmission that has failed - those have a weakness in that area. You can strengthen it, but typically not after it's been damaged. There's an article coming out on this, but it's not been published quite yet. If you email me, I can send it to you direct. - Wayne at Pelican Parts
Comments: Has the Intermediate Shaft Bearing Failure been eliminated? If so, what model year.
Follow-up, which years 05 and later offer the best reliability
April 16, 2013
Followup from the Pelican Staff: The IMS was eliminated in 2009, prior to 2009 it has been used in Porsche engines in some form since the 356. The early bearings are usually the most reliable, 1997 - 1998. - Nick at Pelican Parts
Comments: Am looking at a 2008 Boxster S Convertible 2D. This is truly a gorgeous car. Automatic 6 speed. Only has 10k miles. I want this car, but am worried about something my cousin mentioned about be sure it had "an adjustment" of some kind so the engine doesn't blow. What's he talking about and is that still a problem with this late model of a Boxster?
April 8, 2013
Followup from the Pelican Staff: Not sure, he may be referring to a replacable IMS bearing. I would have a prebuy inspection performed on the vehicle. - Nick at Pelican Parts
Comments: Do you recomend using the synthetic or standard motor oil in the Boxter?
March 28, 2013
Followup from the Pelican Staff: I prefer synthetic oil. The best bet is to use an oil approved by Porsche. Check that this info is up to date: Porsche A40 oil. - Nick at Pelican Parts
Jaguaryea I got one of those to.
Comments: My wifes 97,5spd. boxter blows oil and has very load lifters at start up,after a days sitting.after that time no problem,before that time short time till restartno problem.
The car has 110k miles with a new clutch and waterpump.
How can I start the smoking,it drives me and our condo neighbors crazy
My wife loves the car but I have to do something.We are willing to spend a few thousand to fix the problem,but no one knows what to do.We have had the oil seperator changed out,no fix.?
Can I use a sealent for theradiator to see if it is water related?
March 27, 2013
Followup from the Pelican Staff: Is the car using oil? Check your oil level and see if it is going down over time. It is possible to consume engine oil from a few places. For example, the oil separator, valve stem seals or dirty piston rings. - Nick at Pelican Parts
Comments: I am considering buying a 2000 2.7 L, 5 speed Boxter with 20,000 miles. CARFAX is all OK with gradual mileage progression, but car has had 3 owners, and service records are only available from current owner, back to 2009. Only recent problem is rear seal leak which has been corrected. I can have car checked by Porsche mechanic. In light of engine problems you describe, do you think this is a bad investment? If I buy it should I have IMS upgrade done? Thanks Steve
March 4, 2013
Followup from the Pelican Staff: We recommend the IMS upgrade for your engine. When having the car checked it would be a good idea to check the oil filter for any signs of IMS bearing failure.
- Denny at Pelican Parts
Comments: My boxter 2000s has sat for two months. I briefly started it last week 10 second max with the normal white smoke and noise. I started the car this afternoon again a very loud knocking sound on the right side of the engine has made me very concerned. Even after the car ran idel to operating temp the load knocking noise from the right side of the motor did not go away. What is the ptoblem
March 2, 2013
Followup from the Pelican Staff: If you had no noises in your engine prior to storing it for a few mouths I suspect the lifters have bleed down. You did not state if you drive your car to get the engine temp up or left it idle. Try starting it and running the PRM to around 2500 for a few minuetes or until normal engine temp is acheived. Hopefully the noise will go away. If the noise gains intensity a further diagnosis will be needed. - Denny at Pelican Parts
Comments: I just replaced the AOS on my 37K miles 03 Boxster S because it had the tell-tale symptoms described in this forum. Anyway, the high-pitched screeching sound is gone confirmed by the tear in the diaphragm. However, the car won't stop smoking like a choo choo train. Also, the CEL is on. Any ideas? Thanks
February 20, 2013
Followup from the Pelican Staff: The smoking may be cause by residual oil in the exhaust from the AOS failure. It can sometimes take a good drive and heat to burn the oil out. The only way to tell is drive it and see if the smoke disipates. The check engine light is most probably caused by oil contamination of the oxygen sensors.
- Denny at Pelican Parts
Comments: I have a '97 Boxster. Recently purcased the Durametric diagnostics unit and highly recommed. Need help codes though. I'm currently getting the following P codes: 1123,0153, 1128, 1130. Mixture related but I'm looking for suggestions. Thanks
February 18, 2013
Followup from the Pelican Staff: All of those codes relate to Oxygen sensor signals. I suspect you have an intake leak or the air mass meter has failed causing incorrect fuel mixture. That is a very common problem.
- Denny at Pelican Parts
Comments: Owned a 2003 911 Carrera Cabriolet purchased new with only 26,000 mi. 3000 mi later intermediate shaft failure. Spent $13,000 on new factory motor. Beware 1999-2003 996 Lost all respect for Porsche will never buy one again! Went Audi
February 9, 2013
Followup from the Pelican Staff: I'm sorry to hear that. I hope that others can learn what happened to you. The IMS kits that are available these days do work and do help to prevent this from happening in most cars. - Wayne at Pelican Parts
I have a boxster 97 mod, I have some engin problems, the car is running OK, but when i start the car it come a lot of smoke, and when it get hot the belts are startin skriming, I chance the dynamo, and the belts but it dident help,However it looks like there is high pressure in the oil, dos anybody know what this can be?
January 25, 2013
Followup from the Pelican Staff: I am not completely sure what you mean by your question here. I'll have to make some guesses and some assumptions. When you say there is high pressure in the oil, I think you might mean that there is a lot of vacuum pressure on the oil. This is a sign that the air/oil separator is failing. The smoke you are seeing is also a symptom of this problem. I would check out our tech article on the replacement of the air/oil separator and I would replace this unit ASAP. - Wayne at Pelican Parts
Comments: Man, I'm terrified of my 2007 Boxster S exploding now. It only had 17k miles when I bought it, has another year and a half on the certified warranty, and Porsche told me I didn't need to bring it in for service again until 27k. Right now I'm at 24k and change. Why do they tell people to wait 10k miles between oil changes if 5k is the real requirement? I don't understand what they get out of the deal. Anyway, it runs like a champ but I guess I'll start changing the oil more often. Love the car but I'm worried. :/
January 21, 2013
Followup from the Pelican Staff: . Although I'm not 100% certain I think the reason why Porsche recommends extended oil changes is because the car companies have been pressured by the environmental organizations to reduce the amount of used oil that needs to be recycled each year. In addition to extended oil changes the cars generally run a little bit hotter in order to help evaporate water from the oil. This additional heat does not help the engine either. I still firmly recommend that you replace your oil every 3000 miles, or 5000 at the very latest. Doing this seems to reduce the chances that the intermediate shaft bearing will fail. Also, it would seem that cars that are not driven very hard or very often seem to be most susceptible to the problem. So I would just change my oil often drive the car hard. - Wayne at Pelican Parts
Comments: Dear Sir
I'd like to know if is necessary to fall apart the complete engine boxster S to replace the head gaskets ?
January 16, 2013
Followup from the Pelican Staff: Your question is a little bit confusing, but in ourselves that you mean, "do I need to remove the engine from the car in order to replace the head gasket?" The answer is yes. You can replace the cam cover gasket with the engine in the car but in order to replace the head gaskets, yes, you need to remove the engine from the car. - Wayne at Pelican Parts
Comments: The battery was dead in my 98 boxter i charged the battery, now the engine is backfiring and missing was running fine before
January 15, 2013
Followup from the Pelican Staff: Did you accidentally reverse the battery terminals when reconnecting? Did you remove the battery when you charged it?
I would start by checking the DME for fault codes. If the system is not working properly, a fault code will be set. This will be your best bet when diagnosing. - Nick at Pelican Parts
Comments: currently my wife has a 2001 boxster s as the weather got colder haven't been driving as much. Now shifting between 1 2 3 the engine is over revving before engaging and the engine with a high pitch whine.
January 12, 2013
Followup from the Pelican Staff: Unfortunately, you have an provided me enough information to diagnose this problem. It could be a clutch issue, where the clutch is slipping, if you have a manual transmission. It could be an issue with your automatic transmission, and the fluid inside, if it's slipping before engaging. Off the top of my head, it doesn't seem like it would be an engine issue, the more of a transmission issue. I'm going to copy this question to the forum, and if you can add some more additional information there, perhaps we can help further. - Wayne at Pelican Parts
Presently own '99 Miata with 68k; no issues. Found a '99 boxter with 29k.
It's pretty, seems to drive ok, price not too bad.
I'm tempted but frankly scared of buying car with hidden engine and
reputation for lots of problems.
Maybe I should stick with what I know?
January 11, 2013
Followup from the Pelican Staff: I wouldn't necessarily say that Boxster engines are more or less reliable than Miata engines. However, they are significantly more expensive to replace with something goes wrong with them. If you follow the standard upgrades for the Boxster engine, like replacing the intermediate shaft bearing, and keeping your oil change intervals to about 3000 miles or so, then you should be okay. The good news is that the Boxster's are getting cheaper and cheaper every day, and they are a really huge bang for the buck these days, even when you consider the risk of having engine problems occur in the future. Plus they are really fun cars to drive. - Wayne at Pelican Parts
Comments: I have a 2.5 M96 1997 with 75k and have not had any interventions with anything except usual wear and tear + maintenance, which I lately have done myself.
I drive it all year and the car may not be perfect, but it makes commuting to work on country-roads a pleasure.
January 9, 2013
Followup from the Pelican Staff: Cool. Just make sure you keep your oil change intervals to about 3000 miles, and drive the car hard once in a while. - Wayne at Pelican Parts
Comments: My 2009 2.9 987 with 51,000 miles gives me check oil level warning after about 1 hour running. When checked oil level is at maximum. Is this software malfunction or something more serious?
January 3, 2013
Followup from the Pelican Staff: This is an interesting problem. I could be caused by one of many factors. The first thing that comes to mind is to check the oil level sensor, although if the sensor is defective, I would think it would not be reading correctly when the car was cold. On the other hand, there may be some type of foaming that is occurring inside the engine after it's been running for a while. Your car does not have a dipstick, so it's difficult to look at the oil in the side of the engine to determine. Another thought comes to mind as well. I remember hearing about an air cooled 911 dry sump engine that ran out of oil when it was being driven at high RPMs for an extended period of time. The problem was that the engine was having its oil sucked out of the sump at a rate that was fast enough to replenish its use throughout the engine., But I do know that it was caused by an oil pump that could not keep up. I'm not sure how this relates to your engine, but it certainly is food for thought. - Wayne at Pelican Parts
Comments: I am flirting with the idea of buying a second-hand Boxter S. My pocket dictates that the millage will be over 60,000. Can anyone give me a nightmare-list of potential problems before I part with some hard-earned cash.
December 25, 2012
Followup from the Pelican Staff: These cars are relatively expensive to repair but with Pelican Parts we can save you time and money - Nick at Pelican Parts
Comments: i bought my wife her boxster s new in 05 happy wife happy life 75000 miles later 20-12-12 D-CHUNK, engine failure NEVER NEVER NEVER Purchase a Porsche
£48000 in 2005 £2000 scrap in 2012.
December 24, 2012
Followup from the Pelican Staff: Yes these vehicles are expensive to maintain but with anything high performance it will require more maintenance. - Nick at Pelican Parts
Comments: Hey everyone, I'm thinking of getting a 2007 Boxster with 56,517 miles. A Florida dealer is asking for $24,9668, I checked the Carfax and it's clear, no issues what so ever. Any idea on what I should look for before purchasing it? Cost of oil changes? Typical expenses I should expect and their costs? Am I in danger of getting a car who's engine is going to fail and have me spend $15K soon. Any help/ guidance would be greatly appreciated. I have to let him know by this Sat if he should hold it for me. My other option is a 2009 BMW X5 3.0i for $1,500 more. I'm stumped!
December 19, 2012
Followup from the Pelican Staff: Look at our Porsche Boxter forum and look at the BMW forum and see which cars have more serious problems - Nick at Pelican Parts
Comments: i have a 2001 boxster s, when engine starts and warms up i get a knocking sound from engnie only on idle-tick over, when cold or running at speed there is no knocking
December 8, 2012
Followup from the Pelican Staff: Where is the knocking noise coming from. The Cylinder head? the block? I opened a post in our forums. A Pelican community member may be able to answer your question.
- Nick at Pelican Parts
Comments: What is the head bolt torque on boxster s gasket
November 23, 2012
Followup from the Pelican Staff: These bolts are torque to yield so there is an initial torque setting (30Nm) and then you tighten 3 more times using degrees of rotation. I would grab a repair manual. It will list the special tools and each step of the procedure. Give our parts specialists a call: 1-888-280-7799 They will help you find what you need. - Nick at Pelican Parts
Comments: 2006 Boxter S. Just got it back after spending $3500 to replace a valve spring on #4 cyl. Random? Or a common problem?
November 20, 2012
Followup from the Pelican Staff: It does not appear to be a common problem unless you have an oil lubrication problem - Nick at Pelican Parts
Comments: 99 Boxster w/ 50k miles on it. Never had any problems until a recent "Check Engine" light came on... Read through this post and I'm now convinced my engine is about to explode lol although the car still drives fine... Any thoughts or opinions on what it might be?
November 18, 2012
Followup from the Pelican Staff: Go to an auto parts store. Some of them will pull codes for free and give you the code number. Then come back here and Give our parts specialists a call at 1-888-280-7799. They can help you find the right part. - Nick at Pelican Parts
Comments: I have a 2003 Boxster Base with 35k on it. Just this Spring I had a IMS replacement with the LN part done at 33k as a precaution while they did a oil/water interchanger repair. Just this week, the engine appears to have suffered an engine failure. Sounds like IMS. Unfortunately the dealer who did the work is 1500 miles away now, as we moved. Could it be something else, though it sounded like metallic marbles upon failure. Is it possible to sell the car in its present condition? Obviously very unhappy.
October 22, 2012
Followup from the Pelican Staff: It's pretty difficult to install the LN Engineering kit incorrectly and then run the motor for several thousand miles. So, I would hesitate to blame the IMS bearing in this case. As you can see in this article here, there are plenty of different ways that these engines can self-destruct. I had one in my 2000 Boxster that blew up - the IMS bearing was fine (see the article on engine teardowns). I could never definitively figure out what caused the engine to fail - there was too much destruction. The bad news is that you probably need a new engine. You can sell the car in this condition, but I doubt you would find a buyer willing to pay more than $5K or so for it, unfortunately. I will copy this question to the forums, and the folks there will probably have some additional input for you. - Wayne at Pelican Parts
Comments: My 98 Boxster has loud chirp when running, related to engine rpm. Does not go away when belt is removed. Transmission is also removed right now. Replaced IMS bearing with no effect on chirp. Changed flywheel. Replaced camchain tensioners. Seems to be emanating from cylinder head just behind driver. I'm out of ideas, but hoping for a way to not pull the motor. Any suggestions?
October 18, 2012
Followup from the Pelican Staff: There is a special tool called and engine ear. It is a microphone connected to headphones. while you hear the chirp put the microphone up to the drivers side valve cover and isolate the area of the noise and remove the cover and check for damage. - Nick at Pelican Parts
Comments: 2005 Boxster S. I am the Original Owner only 39,000.00 miles. Engine suffered spun rod bearing due to Oil starvation. Porsche offered ZERO assistance Dealer was no help. I spent 60 G's on my Dream car. Now I have Nothing except the Urge to Puke every time I see a P Car. MAJOR P.O.S. NEVER AGAIN!
October 2, 2012
Followup from the Pelican Staff: Yes as with any car it is buyer beware but our let our forums offer insight for your next car purchase - Nick at Pelican Parts
Comments: A few thoughts: "Using the expertise gained from years of designing and building engines, Porsche developed what is known as the M96 engine for the introduction of the Boxster in 1996." That statement is incorrect. The fact is that the company only has real experience in building engines for racing cars. Apart from the all alloy 944/968 engines the rest of the pruduction types are of VW or Audi basic design. The company does not have the depth of staff to support the expansion it created after 1995. They are good marketeers and so so designers, as far as engineering integrity goes..well ..read above. Don't be fooled and shop around.
September 27, 2012
Followup from the Pelican Staff: This is why Pelican Parts forums offers our readers the ability to make informed decisions - Nick at Pelican Parts
German Car Enthusiast
Comments: Wow!! I was about to order a 2013 Boxster S which with my options came out to $94, 720. I'm glad I didn't order it. I didn't realize Porsche had such shoddy quality and poor customer care. Thanks for "opening my eyes" everyone.
September 21, 2012
Followup from the Pelican Staff: In general, all Porsche cars have had engine problems over the years. Whether it was the issues with the early magnesium cases, or the infamous head stud breakage that happens all the time on the 1980 911s, there have always been problems. These failures are not insurmountable, but they do exist. - Wayne at Pelican Parts
Comments: I have a 2004 Boxster S with only 16,000 miles of light road use. It has just been diagnosed with Intermediate Shaft Bearing failure. After the initial shock wore off, I opted to have it repaired with an aftermarket kit at a cost of $2,000. Two questions: will this repair give a degree of confidence that the problem won't reoccur, or should I fix it and then immediately sell it?
September 19, 2012
Followup from the Pelican Staff: Read the tech article thoroughly and see if lubrication problems may lead to other failures - Nick at Pelican Parts
Comments: I'm in Ozzie & have been hanging for a boxster to import this is the first site I have looked at,...all thoughts for porsche have evaporated absolutely disgusting.
September 17, 2012
Followup from the Pelican Staff: Way to do your homework. This is why we offer these forums - Nick at Pelican Parts
Comments: My husband have a 911 Porsche 2008 or 2009 well his oil light came on it were a quart low with him not knowing he put oil in it he did put the wright kind of oil and the wright amount but a day later the oil start comming out of the pips he read the book that came with the car and it say not to add oil my queastion is what to do ? He is looking for a car place to take it to but I won't to know what to expect now or what he need to do. Can you please tell me? Help!
August 31, 2012
Followup from the Pelican Staff: Did he put the oil in the engine sump or the airbox. It should go into the engine and not the airbox. Look at the "how to change my oil" forum for more answers - Nick at Pelican Parts
elite 5 star
Comments: my engine management light has just come on , i justdid an oil n filter change but they couldnt do a diagnostic check the engine sounds sweet could this just be low octane fuel i put in by mistake .
August 27, 2012
Followup from the Pelican Staff: Possibly but many other problems can cause the check engine light to come on. - Nick at Pelican Parts
Comments: I have an 03 Boxster S with Tiptronic transmission, 47,000 miles At present it is in the shop with the engine removed to enable the mechanics to replace all the vacuum lines, emission control valves , air/oil separator third time and any o-rings , etc., encountered. Personal opinion-I would NEVER purchase another Porsche product-great advertising-poor product reliability, and customer service. This car has been a constant source of aggravation since new.
August 21, 2012
Followup from the Pelican Staff: These cars are high performance cars that require a lot of maintenance, but this is why our forums are here. - Nick at Pelican Parts
Comments: I have a love hate relationship with my 1998 boxster. I purchased it with 18,000 miles on it in 2004. The horn has gone off while the car was parked and I could not stop it, the convertible cable broke while putting the top down and bent the trunk; sometimes the top will not operate unless I full with the emergency brake; the ignition key sticks; and the airbag light stays on. I love driving the car, but am afraid to take far from home for fear of being stranded away from Porsche service people. Time to get away from these unreliable cars. Too bad, I love driving the car. I have done all the services too.
August 13, 2012
Followup from the Pelican Staff: These are high performance cars that require more than a usual amount of maintenance, but this is why our forums are here to help - Nick at Pelican Parts
Comments: i have 97 porsche boxster , which i bought almost new, i have 100,000 mil on the engine , during all these last 14 yrs all i had done to my car was only fuel pump . brakes and oil changes , i think pre soon i have to change spark plus and oh my engine light is on it is time for o2 sensor i have lots fun with this car,
August 10, 2012
Followup from the Pelican Staff: Glad to hear you have had good luck with your car. Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
Comments: After reading all this ,I am too sick to respond. I will try later. 05 987 30,000 miles RIP
August 5, 2012
Followup from the Pelican Staff: Sorry to hear about your bad luck with your car - Nick at Pelican Parts
Comments: My wife recently purchased a low mileage 8400 1999 boxster in beautiful shape. What symptoms should I be on the lookout for?
What are the "must have" upgrades to avoid issues as much as possible?
July 30, 2012
Followup from the Pelican Staff: Inspect the IMS bearing, AOS and water pump. Use the info in the tech article also to decide what you may want to look into. - Nick at Pelican Parts
Comments: I am 80 years old,have driven everything from Harleys to Sherman tanks. Don't laugh had 3 TR3s-they were fun. Kids say I should have a Boxer before I "go". Like to keep it in the 20-25k range. Craig list and a dealer sale would be best. I quess the question is what year were most of the "bug"solved. Excuse My non technical approach
July 23, 2012
Followup from the Pelican Staff: A 2003 - 2004 would be in your price range and are great cars. Most of the kinks were worked out by then. I would suggest asking to view service records of the vehicle and having a pre-buy inspection before you buy it. - Nick at Pelican Parts
Comments: Hello, does anyone have any idea what might have caused my 2003 Boxster to have a hole in the engine after only 75,000 miles?? My mechanic thinks moving metal parts probably caused the crack. I changed my oil much more frequently than the every 15,000 miles recommended by Porsche. I also did the 30,000 and 60,000 miles tune-ups. Aren't these engines supposed to at at least 100,000, if not 200,000 miles? Any guidance would be highly appreciated. I'm attaching a photo of the hole in my Boxster's engine block.
July 4, 2012
Followup from the Pelican Staff: Can you take another photo, a little further back (more of the engine in view). An internal part failing and being thrown around inside can cause an issue like this. No telling how long an engine will last. Usually the joke goes, the least maintained engines last forever, while the engine treated well and maintained fail first. Saying that, I still maintain my vehicles properly and perform all preventive maintenance. - Nick at Pelican Parts
Comments: Currently I have a 01 Tiptronic 103 k & an 02 Manual 130 k knock on wood no problems on either the 02 is a rocketship compared to the 01 got the 02 up to 151mph before I pulled back still had rpm&pedal room to go farther, I did headers exhaust and bypass tubes, short throw shifter eibach pro kit 19/11/295 on rear 19/10/165 on front olds upper strut tower bar, full maston bodykit with wing all around tinted lights lens'&glass all the way around even front windscreen I heard all the horror stories & shudder@times happy I have not experienced any major issues with any of my Porsches over the last 25 years, starting that religious maintenance is the key to a trouble free car? Just ordered oversize intake plenum & throttle body kit, wonder how Mick more performance I'll see?
June 26, 2012
Followup from the Pelican Staff: With a larger intake manifold you may lose some mid-range torque and throttle response but the top end (high RPM) should improve - Nick at Pelican Parts
Comments: Hi Wayne. I am in the market for a Boxster S, probably will go for a 2002 model year with about 53000 km on it. The car is in very good condition and appears to have been well maintained. It is at a dealship. Do you thinik I should have any worries with the engine if I change the oil immediately and change it every 3000 to 5000 kms? I would probably only be putting that many kms on it a year.
June 4, 2012
Followup from the Pelican Staff: Just keep in mind these things were designed for the autobahn and not to sit in traffic. They do need their exercise and religious maintenance. - Nick at Pelican Parts
Comments: hi, just replaced air/oil sep,plugs,coils,on my 1999 2.7 still problem,on the road cars ok,let it tick over, check light on,cod p0300 miss fire,poor running at idle,last point before i scrap,throttle body clean,???? then scrap,can not get, NEW MOT WITH CHECK LIGHT ON,
May 31, 2012
Followup from the Pelican Staff: Throttle body cleaning would be nice. Try running the engine at 2500rpm for 5 to 7 minutes to pump up the lifters and see if it runs smoother. You may have a vacuum leak causing the poor running - Nick at Pelican Parts
Comments: Hi all, I've just taken ownership of a late 2004 987 2.7 tiptronic. When in auto the car gets to 5 th pretty quickly but the revs are low. The car then revs itself slightly whilst at lower speeds and around 2000 rpm? Seems fine when excels rating sharply but doesn't sound good revving up and down whilst travelling at low speed. Any help in identifying what this could be would be greatly appreciated. To be honest I've spent everything on the car wit nothing left for a major repair !
May 22, 2012
Followup from the Pelican Staff: Usually a vacuum leak will cause the engine to surge at idle but not driving down the road. Try cleaning the Mass Air Flow sensor or replacing it - Nick at Pelican Parts
Comments: Thanks for this informative article. Been wanting a used Boxster for 6 yrs now not as daily driver but chose to watch this story evolve and got a new MX-5 instead, then traded up for lightly used M Roadster that I love. Still want a Boxster someday, but would you recommend waiting until a higher performing MY-2009+ falls into my price point so that I don't need $20K in the bank in case of catastophic engine failure? Still seems unpredictable even with a low-mileage M97, which is disconcerting. Appreciate any thoughts.
May 20, 2012
Followup from the Pelican Staff: Hi there. I will copy your question here to the forums, where I'm sure there are many people who will have input on it. - Wayne at Pelican Parts
Comments: Have a 2000 boxter with 35000 miles. Being told that I have a cylinder with 80 # of compression and the others at 145#. Hamisfit give misfire. Changes coils and plugs but no better.Tried to see if they can change the cylinder but it looks like I'm in the lemon group. Tech feels engine will blow up and does not recommend spending any more money on it. Can't believe this is a common issue on these cars. But after reading all and speaking with others it looks very real and this car is now useless.! Porsche seems to know the problem but won't stand behind it.
April 23, 2012
Followup from the Pelican Staff: Unfortunately this vehicle has issues but this is why we have our forums - Nick at Pelican Parts
Comments: Hi everyone. My '03 Boxster had a terrible engine failure on April 8. The service firstly told me that your engine probably became a heck but after a superficial inspection their opinion changed to 'maybe we can save the engine by repairing it' It is obviously an IMS failure. I dont know whether the metal parts of IMS destroyed the engine or not. I was 25mph when it happened However either case is not good. Best chances, if they repair the engine, it will cost 10k$ and no guarantee- maybe they cannot fix it. Worst case scenario is a new engine which is more than 20k$.
I really feel in trouble. If i send an email to Porsche can they help me? Any recommendations?
April 18, 2012
Followup from the Pelican Staff: All of these questions are too difficult to answer? I don't know what Porsche will do, probably nothing. Used motor may have same problem as rebuilt motor. - Nick at Pelican Parts
Comments: I AM CONSIDERING A BOXSTER EITHER AN OLDER ONE OR A RELATIVELY NEWER ONE.DO ALL OF THEM HAVE MAJOR ENGINE ISSUES?I HAVE LOOKED AT ONE98 LOOKS GOOD ENOUGH BUT WHAT SHOULD I DO TO CHECK FOR POSSIBLE ENGINE PROBLEMS /DOES IT NEED 100,000 MILE SERVICE IT HAS 93,000 MILES,I LIKE THE CARTIPTRONIC BUT SHOULD I OPT FRO A NEWER CAR?IF THE ENGINE GOES I WOULD HAVE INVESTED THE SAME $ TOTAL ON AN OLDER MODEL.wHERE TO GO FROM HERE.
April 8, 2012
Followup from the Pelican Staff: It's six of one or half dozen of the other. Have a professional Porsche mechanic check out the cars for you. - Nick at Pelican Parts
Comments: Just recently bought a 1999 Porsche Boxster, check engine light came on when I was bringing it in for an oil change. Put on computer, only came back with a dirty sensor. Mechanic cleaned, reset and changed oil. Have driven Porsche only a few times since then, and check engine light came back on and it seems to be running hotter now. Any suggestions?
March 29, 2012
Followup from the Pelican Staff: Check your cooling system, water pump, thermostat and cooling fluid level - Nick at Pelican Parts
Comments: I have 2001 Boxster with auto tiptronic trany.. i was driving it he other day and it acts like it is stuck in 3rd gear. i moved it to drive in tiptronics and it's not shifting. light keeps blinking on the 4..spoiler popped up and will not go down..Whats going on ..one person said assembly cluster and another said it was in the shifter..Don't kn ow what to do at this point.
March 29, 2012
Followup from the Pelican Staff: You have to check for diagnostic trouble codes in the tiptronic transmission control unit and have them cleared - Nick at Pelican Parts
Comments: 2001 Boxster base, 35k miles. I bought oil filter, billet alum. magnetic plug, etc from Pelican. I used Mobil 1 0w-40. Is my oil choice a mistake? I live in Ohio and I rarely drive in the cold weather. i bought the synthetic oil at an Autozone store whose computer showed it as an approved porsche brand and type.
March 13, 2012
Followup from the Pelican Staff: The oil you mention is a 0 weight oil when cold and a 40 weight oil when hot. You probably don't need something this thin especially in warmer weather. A 5w-40 or 10w-40 would not hurt but stay on top of the oil changes - Nick at Pelican Parts
Comments: WOW very interesting; I am about the purschase my first Porsche Boxster 1999 2.5 engine: I have test drove it several time; I have research carfax; but after reading other sites about their problems I'm wreary about to purchase; for the car to be 12 years old and only 52,000 mile made be want to buy it knowing German cars are built to for the long haul. I always buy used cars and do you recommend that I have the soarks plug change and oil change with the other fluids; the car runs very good its the gamble as always with used cars; the next few months; I'm not a hard driver nor do I drive long distance evern though I will be driving everyday about 25 miles per day
February 26, 2012
Followup from the Pelican Staff: Remember these cars were designed for the Autobahn and not to sit in traffic for 30 minutes and stay on top of the maintenance. - Nick at Pelican Parts
Comments: i have rebuilt my 2003 boxter engine because of an ims shaft failure.. i can get to start but engine does not run long the three cyls on driver side quit doing there job... has any one had this problem? possible variocam or cam sensor? i have pulled engine and rechecked cam timing...
February 3, 2012
Followup from the Pelican Staff: Check compression in one of the cylinders that are working and the three that are not. Also verify you have spark, injector pulse for those three cylinders. - Nick at Pelican Parts
Comments: when porsche boxster has a blow from the exhaust what could it be? but the blow gos after a bit dont under stand!! so is it just the exhaust????
January 4, 2012
Followup from the Pelican Staff: I assume you mean backfire. This could be cause by the cylinder not firing and the exhaust igniting the mixture as it leaves. You could have a burnt exhaust valve. Check compression in each cylinder - Nick at Pelican Parts
Comments: Very good information. I have a 2000 Boxster S fabricated in Germany. It has 13,000 miles on it. Any recommendations or things to look out for and avoid with the identified problems? Is the 2000 S immune due to design changes to any of these problems? Thank you.
January 3, 2012
Followup from the Pelican Staff: Yes the engine does have some factory improvements. Stay on top of the oil changes avoid sitting in traffic as these cars were designed to run on an Autobahn. - Nick at Pelican Parts
Comments: I appreciate all the advice. I have always wanted to get to purchase a Porsche Boxster. I was not aware off all the issues being mentioned. I recently test drove a 1997 Boxster with 8000 miles. It sees from the noted comments that it is a russian roulette situation whether there is little mileage on vehicle or high mileage. Any advice? Dont get it?
December 13, 2011
Followup from the Pelican Staff: In 8000 miles, not too much could have gone wrong already. I would not worry about it. I would buy the car, change the oil immediately, and then keep changing it every 3000-5000 miles max. I think you'll have a car that will last a long, long time. - Wayne at Pelican Parts
Comments: Your information made it a lot easier to choose between the Boxster and the MX5 ! sorry Porsche
November 26, 2011
Followup from the Pelican Staff: Hmmm, my guess is that you haven't had the opportunity to drive a Boxster? Most people who actually drive them end up choosing them. In my opinion, there is no comparison between the two. - Wayne at Pelican Parts
Comments: Wow...this tread has given me some new things to consider with regards to 3 blown engines 3 years with a Saabaru 2005 9-3x aero. I have been told over and over by Saab that it was caused by me switching to full synthetic oil and I should only be running Dino oil changed every 7,500! in the Boxer i.e. NOT Boxter engine in my car, especially since I constantly run high RPMs.
November 19, 2011
Followup from the Pelican Staff: How did they explain to you that full-synthetic oil offers worse protection? Synthetic oil can withstand higher temperatures and therefore offer similar lubrication qualities hot or cold. If you are going to drive like you have a high performance car you are going to have to do more maintenance. - Nick at Pelican Parts
Comments: I have a 2001 Boxster S with the 3.2L motor. I was recently driving at moderate speed. When I looked at the gauges, the temp needle was about maxed and the motor died. The head gasket failed. Do I assume it is dead and buried? What is my best path from here? Replace the motor? Too far gone for rebuild?
November 13, 2011
Followup from the Pelican Staff: Hmm, that is unfortunate. I would say yes, your engine is pretty much shot and you either need a new one, or you can rebuild the existing one. I'm not sure which method is cheapest these days, it all depends upon if you can find a good used 3.2 S engine. - Wayne at Pelican Parts
Comments: I have a Boxster 1997 2.5 ,I recently purchased vehicle but have been strugling to get reverse gear now i cannot get reverse all other gears are fine
Comments: According to this website, Boxster engines are an absolute nightmare. I have a 2001 Boxster and touch wood never had a problem in a year. Reading the suff on here though doesn't fill me with confidence and it can ruin the driving experience worrying the engine is about to self-destruct at any moment. Wish I'd never read this crap now.
September 6, 2011
Followup from the Pelican Staff: Porsche engines throughout the years have always had problems and issues - the Boxster engine / drivetrain is nothing new. There have been a bunch of failure of the Intermediate Shaft Bearin (IMS Bearing) over the years, but that is now repairable with aftermarket kits. I think the important thing to remember is to change your oil every 3,000 miles or so. - Wayne at Pelican Parts
Comments: Waynem I have a used 1998 Boxster that I recently purchased.
I have had it tuned up and services by a reliable independent mechanic in Jacksonville. Fl. I spent approximately $2700 on the turn up and front break over hall. I have subsequently developed a loud chirp when the engine gets warmed up. I have been told that I need to replace the water pump and possibly the AC compressor. Can you shed in light on what might cause my car to chirp. By the way the temp gauge has never indicated overheating and stays in the 160 to 180 range. Before I spend any additional money on repairs, I need a second opinion. Thanks
September 4, 2011
Followup from the Pelican Staff: A chirp as you describe it typically means a squeaky bearing somewhere along where the belt runs. That is why your mechanic was talking about the A/C compressor or the water pump. In reality, it may just be an idler pulley, you can see the procedure for replacing them in my other article here: http://www.pelicanparts.com/techarticles/Boxster_Tech/17-ENGINE-Idler_Pullies/17-ENGINE-Idler_Pullies.htm You might have to do some trial and error to figure out where the sound is coming from - I typically like to spray WD-40 on each bearing to try to figure out where the sound is coming from. Others might have suggestions - I'll copy this question to the forums. - Wayne at Pelican Parts
Comments: hi i have a 1999 boxster, i have had it a few months now and it has run great. up to last week. now whenever i accelerate and my rpm gauge reaches 4,000 rpm the engine stalls and drops down to around 2,500 rpm. i had my car smogged a few weeks ago and found that the O2 censor is not working. could this be causing my computer to be on limit mode and not working properly??
Comments: Hi, I have a 2003 996, when the car reaches 200F stalls and doesn't start and I see the rpm idles up and down even though the car is not running. But when it's cold it runs very smooth and fine. I replaced the crank position sensor still the same and just put a new dme and still the same way. Any idea's of what would be the problem?
Comments: Hello I would first like to commend the very it at all times is a possibility of my Porsche Boxster 2.5 bj 99 a couple of photos and information on bekommen.Hier in Germany it is not even possible to have some information from the workshop to complete all bekommen.Die fear of losing their job pisses me off all here, all top secret ... do not even get the torque of my clutch I want to install as soon as possible ... they can help me and give me a list of times the torque of the coupling and valve cover it schicken.wδre not even possible to translate the whole thing in German and to bring in the internet .... love .... many greetings from Hessen Bebra Ricco
Umschrift ricco franz
May 5, 2011
Followup from the Pelican Staff: I would grab a repair manual. It will list the special tools and each step of the procedure. Give our parts specialists a call: 1-888-280-7799 They will help you find what you need. I opened a post in our forums. A Pelican community member may be able to answer your question.
- Nick at Pelican Parts
Comments: I have a 2000 2.7L Boxster that I replaced the head gaskets on trying to fix an oil in coolant problem. This didn't fix it and I'd like to know if the 2.7L engine can develop the same cylinder liner cracks as the 2.5 & 3.4L engines. What is the cost to machine the case and replace the cylinders with Nikasil cylinders?
March 17, 2011
Followup from the Pelican Staff: Yes, these engines too can experience the cylinder liner cracking that you mention. LN Engineering does the replacement of the liners with new ones - I'm not sure what they charge for the procedure, but as you might imagine, it's not terribly inexpensive. - Wayne at Pelican Parts
Comments: Wayne at Pelican Parts
Porsche is offering a 50% offer at a $13K engine replacement for my Boxster with 32K mi, bought new. Do I get the new bearing?
September 21, 2010
Followup from the Pelican Staff: The new factory rebuilt engines come with the latest-style bearing, so I would guess yes. However, I'm not 100% sure that this new bearing completely solves the problem. Time will tell! - Wayne at Pelican Parts
Comments: It seems that the M96 engine is the problem. With regards to the major IMS failures; what model years of the Boxster have been modified to avoid catostophic engine failure.
June 10, 2010
Followup from the Pelican Staff: With respect to the M96 and M97 engines - they all seem to have failures all over the place. No one has quite figured out what the issues are and exactly what causes the bearing to fail. You can have a 31,000 mile car with a failure, and a 131,000 mile car with no failure. Frequent oil changes seem to help. Around 2006, Porsche went to the larger non-replaceable bearing which is supposedly better, but there still have been reports of this bearing failing too. - Wayne at Pelican Parts
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