996 ENGINE FAILURES? Yep. Trashed Engine last week - help!!!

[3.8RSR]

Trashed engine last week at 110,000km.

Thanks to all who can contribute advice in dealing with this.

Details:
A good friend has owned his '98 996 Tip for 5 years, and just rang me yesterday for advice. Porsche just advised his engine case is cracked quoted him $A24,000 for an exchange engine!

His car is 100% factory serviced every 10,000km which is better than required, and has just experienced a destroyed engine less than 3 mins from home on a cold morning.

He had the car serviced by official Porsche centre only two weeks before, and went OS on business for a week, leaving the car at home. Upon return, drove off to work, cruising at only 70kph. Still warming up, the car then lost power fairly suddenly, without any symptoms, all gauges temps, pressures seemed normal, no overheating of course, NO warning lights on. He then slowed to about 20km/h, with no power, pulled over to the side, then the engine light came on after a few moments. Arranged tow truck and taxi, straight to Porsche.

Porsche pulled plugs and noted water in the cylinders on one bank, and drips from heads on other bank. Leaking like a sive they said. They pulled the engine and removed one head, and reported a cracked cylinder...bad bad 996 news.

Not repairable they said!!! No offer to rebuild. No options given other than "U need a new engine sir". $62,000 new or $24,000 exchange airfreighted from Germany.

So yesterday I rang a highly respected independent Porsche shop and they suggested this is a problem in early 996s... head gaskets fail causing a hydraulic lock situation, and this pressure commonly blows the 996’s thin walls of the cylinders which is the engine block in a 996. Also common in 928GTS's he said.

Can all 996 owners expect a destroyed engine when a cylinder head gasket finally goes?
eg this is normal in old cars for gaskets to eventially fail. Ok then, say overheating or loss of compression to be expected, that's one thing, even say warped heads maybe, but to hear expect a DESTROYED ENGINE IN A PORSCHE???

Cam tensioners problems and head studs on a 2.7 911 I can accept. But I cannot accept not blown engines due to a simple gasket failures if this can strike ANYONE at ANYTIME???

Questions:
1. Should Porsche service centre be responsible since they (a) have always serviced this car 5 years and $$$ and (b) just serviced the car so recently and did not report any problems?

ie What DO the factory do in their $115.00 per hour services? Rub their hands together as they log the milage??? Sorry I am very cranky about this.

2. Is the Porsche Factory somehow responsible in someway? (If this a known problem)
ie. Should the factory specify all 996 head gaskets be changed like a timing belt in a Honda... say at 60,000km or earlier if this problem is to be prevented.

What about regular compression tests? Should this be a mandatory check & maintance expected by a Porsche centre when (I am assuming...) cracked 996 engines and head gaskets are a "known issue"?

Thanks in advance for your comments and advice.

The new engine is now on order. It is cheaper than a rebuild aparently, even with airfreight. And you do get a 2 year warranty for your $24,000.

[RickM]

I'd talk to the Porsche regional director and explain the situation. Here in the states they typically bend over backwards to help. Your local Porsche club chapter should be able to help with a name and number.

If it is indeed a widespread problem then a class action lawsuit may be appropriate.

[MotoSook]

Seems that the factory should replace the engine. It's a flawed design...no way should one live with the time bomb, then hope the dealer/factory will be generous when the thing blows up! The factory has replaced failed engines for lesser reasons.

Not to change the topic, but I just read Bruce Anderson's Boxster/996 article in excellance, and I was VERY surprised to read about all the problems with the pre-2000 Boxster engines. I was aware of the porous cases, but not the cylinder sleeve proble...talk about a poor fix! The message I got...buy an early Boxster and wait for the sleeves to drop into the case! I was shopping for a cheap 2.5 Boxster, but hell no....the problems are not acceptable...and a second hand Boxster will never receive fair treatment from the factory.

[Iggy]

Originally posted by 3.8RSR
Also common in 928GTS's he said.

After 4 years of ownership and 3,500+ posts over on the Rennlist 928 forum, I've never heard of this happening to a 928.

Is it possible to just replace the block or does it have to be the whole engine?

[Plavan]

Read my footer.......
I was lucky enough to have 4 RMS leaks (2 on the Boxster and 2 on the 996). I dumped both cars and ran!

[TRE Cup]

We've replaced 2 motors due to cracked cylinder sleeves on 996's. No abuse, no lack of maintenance- just regular everyday driving. We do not recommend the purchase of pre-2001 water pumpers because of this. Some of the cars "blew up" on their owners fairly early on and the dealers replaced engines very quickly and very quietly. Perhaps finding one of these "improved" engine swapped models would be acceptable to buy.
Tell your friend to find a newer used motor here in the states and convert it over for install in his car (later engines had e-gas throttle control). He could probably get one shipped to him for around $10k us

[Gus Berges]

Are 2002 and newer models (3.6L) not prone to these failures? I do know the RMS is still an issue, but was unaware of the cylinder sleeve issue. Thanks.

[Neilk]

I would have suggested getting a used engine, but your friend already has one on order. With 996 engines useless to the air cooled crowd, I bet you could get a great deal on a used one.

[Par911]

Rear main seal

[carnutzzz]

Same thing happened to one of my employees. He got a replacement engine and sold the car.

[kenikh]

CRIPES; my dad has a '99 996 w/ ~40K miles. He is not a gearhead, just a car lover. He bought the car two years ago on my recommendation as he wanted a modern and reliable Porsche (I tried to get him into an air cooled car).

What are the alternatives here? It seems there must be an improvement made in later parts that could be installed preemptively to make sure this never happens. Would an option be to replace the RMS and other gaskets now? Is there any assurance this would dodge the bullet? I am a bit freaked by this. My dad could afford a $24K engine, but he'd be more than a little pissed, especially if it could have been avoided.

Porsche AG, please speak up and own up to this mess!

[anthony]

What is the exchange rate for US to Australia? $24A sounds so high. Last I heard a new factory 996 engine was $7,500 in the US. Did I hear wrong?

[kenikh]

Small consolation to a blatant F#@K up by the Porsche engineers, but that makes me feel somewhat better. I am going to tell him to sell the sucker and buy a 997 Carrera S.

[Speedster94]

hallo
Do you think the 997 is any better ,using most of the 996 Stuff ?
There are rumours that the factory has a new seal-ring available in August and they claim that will cure it . But that has been said everytime they had areplacement ( about 7 Times now )
The only solution is to stick with the Aircooled Engines or if it has to be WC than GT3 or Turbo as they are using the 964/993 Blocks/ Cranks .
Harald

[Noel]

When Excellence tested the new 987 Boxster S they reported waking up to find a large puddle of oil under the car. It was the rear main seal (RMS) that failed and needed replacement. It doesn’t sound like Porsche has fixed this problem yet. This is unacceptable for such an expensive car!!!

[84porsche]

Does automotive insurance cover something like this under a comprehensive policy??

[MotoSook]

Originally posted by 84porsche
Does automotive insurance cover something like this under a comprehensive policy??

I would highly doubt that. Otherwise, folks would be over-revving their engines or finding some other destructive means to get a new-fresh engine.

[Noel]

Originally posted by 84porsche
Does automotive insurance cover something like this under a comprehensive policy??

It's bad enough that people really think a track accident should be covered. No WAY!!!

[TRE Cup]

hmmm... we've seen a few motors that found curbs and speed bumps- which is covered by insurance

[84porsche]

I think their is a major difference between having an engine defect which causes the engine to fail completely and a track incident. Track incidents are different but no matter how damage occurs it should be insured in my opinion. By insurance, track specific insurance not normal everyday driving insurance. If insurance won't cover something like this then I want a performance service plan or something comparable.

I pay $3,000+ a year for full coverage insurance for 2 cars and if I file one claim within a 10 year period, it more than pays for itself. Why else would I paying someone to protect my automobile besides the fact that it is required in the state of CA? Especially comprehensive which covers the car from any mishaps.