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.

http://www.pelicanparts.com/more_inf...52393-1128.jpg

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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

Well the timing chains act like conveyer belts. taking things
from the bottom front of the engine into the cam housings (heads)

A bolt or nut might have worked its way loose and rode up the chain
then played foozeball inside your cam housing until one of the cam lobes
struck it into the side either one too many times -- or it was big enough
to lodge against the lobe and sidewall and punch its way through.

Downside is that the cam housing is matched to the cam cover (the camshafts
journals are bored out together). You'll have to figure out where the bolt came from
then source a replacement head and valve cover.

I'm suspecting the finding of where the bolt came from maybe more intrusive.

Any collateral damage?

Alternatively you can source a replacement engine.

mike

Mike

Your options are here. And yes, many Boxster engines go 200k but think of failure frequencies as a bell curve, some fail on either end.

It could be just bad casting, a better pic of it would help. From here it doesn't look stressed from the inside.

If that is the Cam cover in the pic you may be able to find a used replacement cover that fits acceptably with the head & cams. You will need to do a trial assembly & check the cam bore alignment & clearance. However the engine will need to be completely disassembled, throughly cleaned & inspected for excessive wear of all parts & find the pieces that caused the damage! :eek:

i agree with the suggestions offered by others. if my own car developed ahole like this i would remove the engine, or have someone do it, and conduct a thorough inspection and disassembly as needed to get to the cause. At that point an assessment of repairs and options can be formulated
Good Luck