2000 Boxster 2.7L Engine Failure

[kellyclark]

On Tuesday evening March 11, 2008, the engine of my 2000 Porsche Boxster (5 speed manual) suddenly began blowing large amounts of smoke and shut off abruptly. I had the car promptly towed to a trusted and experienced Porsche mechanic. He removed the lower oil pan and diagnosed that the oil strainer became clogged with silicone sealant, which had broken off from inside the pan. This constricted the oil flow and caused the engine to seize. I'm adding some pictures to show how this looked.

The mechanic confirmed that this problem should be considered a manufacturing or repair issue that could not be prevented with regular maintenance. Nothing abnormal such as warning lights or increase in temperature indicated an impending problem. I purchased the car with only 22,000 miles on it and it still has less than 100,000 miles. The car was serviced just 7,000 miles ago and I noted the oil level was full that evening, having filled the gas tank just 2 miles prior to engine failure. I have maintained the car to the letter of the service manual, and the mechanic stated that the engine was otherwise in excellent shape, noting how the engine's oil and other components showed no indication of other issues.

After reviewing my service records, I realized that the my local dealership in Atlanta, Georgia, which serviced the car regularly, replaced numerous gaskets and sealant applications under warranty at the scheduled 30,000 mile service on February 21, 2003. I asked the service manager at the dealership, who was also working there in 2003, if techician error could have caused this problem. Of course, he denied that possibility.

Two weeks ago, I addressed a letter to the Manager of Customer Commitment with Porsche Cars North America outlining my car's situation and asking for Porsche's help to repair my engine. After all the supporting information, photographs of the engine and supporting documentation I provided, Porsche flatly declined to help repair my engine.

So I wanted to make others aware of this potential problem, in case you own or are considering the purchase of a used 986. Hopefully you can use this information to avoid the great disappointment I've expereinced with my car.

Kelly

[bmohr]

fk..that doesn't look good:( Sorry to hear about your troubles Kellyclark. I commend you on trying to get porsche to get off their asses and help out..too bad they don't delve into their enormous profits to help these cases out a bit. A little corporate love/help would go LONG way with keeping people in the marque.

bmohr

[smiledrs]

I feel for you. I had my engine go out on my 1998 Boxster with only 22,100 miles last Aug. PNA said the same thing in a letter when I asked for help toward a new engine. They turn a blind eye and act like nothing is wrong, yet there are numerous accounts of engine failures with very low miles. I wound up putting a 3.4L 996 engine to give me more horsepower and a more spirited drive. Hope things work out for you.

[wvicary]

Could it be possible that the mechanic who did the old repair caused this problem? Sounds like you have an issue with the dealer and not PCNA. Sorry to hear about your troubles.

[efedor]

I also feel it was a mech failure and not Porsche's fault. A mechanic could of easily put too much silicone or sealant and when he tighten the bolts/nut the silicone was squeezed out and the remainder was pushed in into the engine casing and out of the engine casing. This is clearly a mechanic error. What kind of repairs do you have to get done to the car so it can be back in running condition? Good luck

Edited April 2, 2008 by Loren
Removed ALL CAPS - please do not post in ALL CAPS

[dcporsche99]

Sorry to hear....ouch!! :o Is that the crud (around the mesh) that collected??

Good luck with that!

Thanks for sharing!!

[hooster]

Although this might be an event for a financial loss...think of it this way...time to upgrade to a 3.4 or 3.6 Liter engine!!! No better excuse.

[magcuda]

this is a dealership issue, PCNA usually doesn't touch this type thing. second owner way out of warranty

now the 97-98 Boxsters PCNA knows there is a problem with them, cylinder liner slipping, they replaced enough engines back then. but once again they don't do much for second owners.

[catmanluge]

this is a dealership issue, PCNA usually doesn't touch this type thing. second owner way out of warranty

now the 97-98 Boxsters PCNA knows there is a problem with them, cylinder liner slipping, they replaced enough engines back then. but once again they don't do much for second owners.

WOW!

[Topless]

So the real question is, who was the Bozo that squeezed out a 3oz tube of silicone just to change the pan gasket??? <_<