Yellow sludge in coolant

Phakeflyer · 02-23-2019, 06:44 AM

I have a 2003 Boxter S 60K miles and found a milky yellow sludge in my coolant, took it to the Porsche dealer who did a leak down and oil cooler test, both were OK. The service dept pulled the plug and determined " new engine required, cracks in the block suspected, $19,000 please!" I have seen posts about other cars with the yellow sludge due to mixing or cheap antifreeze which due to my ignorance is a definite possibility. I'm skeptical about accepting cracks in block without definite proof, but will accept inevitability if no one has any other thoughts. I've looked into replacement engines, but don't want to buy a used engine just to go through the " bad engine scenario" again a short time later. Is it worth it to replace the block and rebuild the engine, or bite the bullet and offer the car up for parts? Any suggestions?

Brian in Tucson · 03-11-2019, 03:23 PM

Sorry for not getting back to you. Surprising nobody responded.

So what do they suggest is wrong with the engine? Cracked head? Did they pull the oil pan? Or at least drain the oil to see what it looked like? Pull and inspect the oil filter?

I wouldn't take it to the parts replacers at the dealer, Indie shops generally fix things and some even try to be economical. Have it flat bedded. If it were my car, I'd pull the engine, put it onto an engine stand and do a teardown to see if it can be salvaged. Parts are really expensive, but when you're talking upwards of $10,000 that number will buy a lot of parts

https://lnengineering.com/rnd-store/rnd-engines-rebuild-services/rnd-engines-direct-replacement-3-2l-engine-for-03-04-porsche-boxster-s-04-boxster-s-special-edition.html

mikefocke · 03-11-2019, 04:16 PM

Take to a shop that has Porsche water cooled internals experience (by flatbed). Heads can be replaced or even repaired.

And read this.

Good luck.

tonythetarga · 03-12-2019, 05:44 AM

Agree with Mike. BUT...don’t keep that sludge in the system. I redid a car with an oil intermix, which is what they are saying occurred. That crap is impossible to get out. I had to replace all the coolant lines to the tune of $1500.

Phakeflyer · 03-31-2019, 06:09 AM

The dealer did a leak down test and checked the oil cooler system and from that point on relied on protocol with engine replacement. There is no water in the oil, but tried flushing the bad radiator fluid out with several flushes and drainings, oil just keeps mixing in, so bad fluid or condensation seems unlikely. Did a lot of research and agree that replacing the engine with one from a wrecked car doesn't necessarily mean that 20 miles down the road I won't have the same issues. Found several rebuilders with engines running about 10K, plus or minus about 2K, add in the extra parts......think I'm looking for a new (to me) car sometime in the future. Just found water leaking from the pump, I'm guessing that would not be the cause of the original problem, just an additional one. Thanks for the responses!

Brian in Tucson · 03-31-2019, 07:06 AM

Quote:

Originally Posted by Phakeflyer

The dealer did a leak down test and checked the oil cooler system and from that point on relied on protocol with engine replacement. There is no water in the oil, but tried flushing the bad radiator fluid out with several flushes and drainings, oil just keeps mixing in, so bad fluid or condensation seems unlikely. Did a lot of research and agree that replacing the engine with one from a wrecked car doesn't necessarily mean that 20 miles down the road I won't have the same issues. Found several rebuilders with engines running about 10K, plus or minus about 2K, add in the extra parts......think I'm looking for a new (to me) car sometime in the future. Just found water leaking from the pump, I'm guessing that would not be the cause of the original problem, just an additional one. Thanks for the responses!

It's been so long, I forgot I responded to your post. You're planning on getting another car soon? In that case, I'd suggest that you sell off the car as a roller, upfront about the dead engine. It IS dead. Probably can get about $3000 for it. Put that with the $6000+ that a used replacement engine would cost (that's a low estimate) and you have a pretty good start at another car.

I'm crazy enough that I would buy something like this with the plan to put another engine in. But I wouldn't suggest it to anyone else. Even as a DYI, it's expensive and very complicated and time consuming.

Whatever. Good luck whatever you decide.