Until recently, Porsche tended to treat the engine and transmissions as ‘sealed units’ and in the event · of problems would replac

Notes Until recently, Porsche tended to treat the engine and transmissions as ‘sealed units’ and in the event of problems would replace them rather than repair them if faulty. Some parts of the original 3.4 engine are no longer available. An example of this is the intermediate shaft, whereby it is now necessary to replace not only the shaft (with the new strengthened shaft) but also the crankshaft. However, independent specialists have recently come up with less costly solutions if an engine or gearbox has failed out of warranty. The collapse of the top edge of one of the cylinder walls is a rare but costly problem with the M96 engine block, which seems to be less common in the 3.6 than in the 3.4. In almost all cases it is the centre cylinder (of either bank) affected, usually happening between about 15,000 and 50,000 miles. This is thought to arise due to a lack of rigidity between the block itself and the integral Lokasil liner. The problem manifests itself with cross-contamination of the engine oil and coolant, followed by excessive steam coming out of the exhaust. If the coolant header tank has an oily residue then you definitely have a problem. If the car does have a cylinder block failure you can buy an exchange re- manufactured engine from Porsche (around £8,000+fitting) or a second hand unit (around £3,500) from a specialist dismantler. Another option would be to go for a Silsleeve conversion from Oxfordshire based Autofarm (around £8,000+fitting) which uses a re-engineered crankcase with specially designed liners and a redesigned drive on the intermediate shaft. However, Hartech in Bolton are probably the most innovative rebuilders of these engines, and have come up with some very cost effective solutions for repairing and strengthening the weak points of the engine. Another rare problem is with intermediate shaft bearing failures leading to engine failure. A modified intermediate shaft with a larger end bearing was introduced in 2001, making these engines less susceptible, but not immune, to the problem. You have to remember that Porsche manufactured in the region of half a million of this series of engines, and the huge majority have performed flawlessly. Whilst it is a serious issue if it happens to you, the extent of the issue can be distorted by reading the forums. No one ever joins a forum to report that they have had no problems at all! Prices quoted are approximate (02/07), and from independents, including fitting unless stated. Thanks are extended to Wrightune and Jaz for their help in compiling this checklist. www.wrightune.co.uk and www.jazweb.co.uk Richard Hamilton and Rodney Naghar February 2007 (with minor updates 12/09 and 03/10)