MY2002 996 Engine Failure! PNA To Cover Replacement...

When I started my 2002 996 Cab yesterday afternoon, I noticed a ringing bicycle bell type of noise coming from the engine compartment. <img border="0" title="" alt="[Eek!]" src="eek.gif" /> The ringing noise got louder with a blip of the throttle, and came to a crescendoed stop upon turning the ignition off. I had Porsche roadside assistance pick it up and take it to my local dealer, where it's being looked at today or tomorrow. Any ideas as to what is? An issue with a connecting rod or valve? A known issue with PNA? Every now and then on startup (1 out of 50), I get a huge plume of smoke (enough to completely fill a 200 sq ft room), which I'm told is from oil seeping past the valves into the engine compartment. Could it be related? Thanks

Geez, that's strange. Pls keep us posted. :-o

That's strange indeed Back up specialists???

yipe

Just listened to the dealer's message that the engine is going to have to be replaced! Poor engine had a life of 10,025 miles, but what miles they were! In the message, the dealer also stated that Porsche would replace the engine with a factory rebuilt one... but one question, any chance that I can ask for an X50 or GT3 engine instead, for an upgraded (and discounted) price? How much would extra do you think a rebuilt X50 engine would cost? I will talk to the dealer about this today, and give an update. Has anyone heard of this issue with a low mileage 2002 C2 Cab? I guess I'm fine with the issue, as everything's being covered by PNA, and I'm driving in a brand new Boxster loaner. BTW, the Boxster makes a great city car, when you need a fun alternative to the 996! Cheers Cydog

You would have better luck working it with the X50 engine as opposed to the GT3 engine. The GT3 engine is a different animal altogether. I would certainly ask about the X50 engine... the worst they can do is say no. good luck.

Sorry, but I'm a bit confused. Did you mean you were going to ask for an X51 package engine? I thought the X50 was the twin turbocharged package engine. I would imagine that fitting the intercoolers into a narrow body 996 would be a challenge for the dealer.

Doesn't anyone think it is ridiculous that a one year old motor with just over 10K on the clock needs to be replaced? What's up with that? What is happening to "German" engineering?

</font><blockquote><font size="1" face="Verdana,Tahoma,Helvetica">quote:</font><hr /><font size="2" face="Verdana,Tahoma,Helvetica">Originally posted by adscab911: <strong>Doesn't anyone think it is ridiculous that a one year old motor with just over 10K on the clock needs to be replaced? What's up with that? What is happening to "German" engineering?</strong></font><hr /></blockquote><font size="2" face="Verdana,Tahoma,Helvetica">European Car magazine reported last month that their long-term tester ('02 C2) had it's engine replaced with less than 7k miles. The postmortem from the factory was a failed auxiliary shaft bearing.

Cydog, what was the dealer's diagnosis?

Don, The dealer has just diagnosed it as major engine failure, without opening it up. I guess that bicycle bell noise reasily translates into some sort of major failure in which case we both would be better off with a rebuilt engine. Any reason to have any misgivings about a rebuilt engine, except for the fact that it needs to be broken in again? BTW, I got the car with 7500 miles on it, so who knows what was going on before me.

Man that really is a downer-well once it gets fixed up-all is good. Yeah it wouldn't hurt to ask if you can upgrade to the x51 powerkit since a new engine is coming. Regards and good luck. Mike

tell us if you can work that it will be good to know what our options are!

GT3 uses a different tranny, so I'd say that option is out...

</font><blockquote><font size="1" face="Verdana,Tahoma,Helvetica">quote:</font><hr /><font size="2" face="Verdana,Tahoma,Helvetica">Originally posted by adscab911: <strong>Doesn't anyone think it is ridiculous that a one year old motor with just over 10K on the clock needs to be replaced? What's up with that? What is happening to "German" engineering?</strong></font><hr /></blockquote><font size="2" face="Verdana,Tahoma,Helvetica">I have seen a TT in the dealer's workshop without engine??? done 10,000 km only, they send the engine to Germany for replacement, they even don't know and will never know the reason of the failure as i was told by the workshop manager.

</font><blockquote><font size="1" face="Verdana,Tahoma,Helvetica">quote:</font><hr /><font size="2" face="Verdana,Tahoma,Helvetica">Originally posted by adscab911: <strong>Doesn't anyone think it is ridiculous that a one year old motor with just over 10K on the clock needs to be replaced? What's up with that? What is happening to "German" engineering?</strong></font><hr /></blockquote><font size="2" face="Verdana,Tahoma,Helvetica">If this was the only one, it would't be ridiculous but since this isn't, it in deed, is very much ridiculous.

Update: They don't know if they can do an X51 (not X50) upgrade, and is still being looked into. So here's a question... I would be cool with a rebuilt X51 engine at an extra price, but not with a rebuilt standard engine. Why should I accept a rebuilt replacement part, which IMHO is still a used part, instead of a completely new replacement part. Thoughts!? Am I being unreasonable? I'm going to have to pull out and read the warranty.

here is a question to consider. with airplane engines, there are rebuilds, and then there are rebuilds. your engine core has 10,000 miles on it. it is possible, if this is an issue, that you may get back a rebuilt engine with far more hours on it. again, i don't know if this is an issue with auto rebuilds. if it is, check into just what they replace on the rebuild, or get a brand new engine.

There is nothing wrong with a rebuilt engine if its from Porsche in Germany, it doesn't get any better than that. We're not talking about a rebuilt from the local auto parts store. I would take it and be happy that the car was under warranty and it costs you nothing. Keep in mind that you are still under warranty after they put that motor in and it will look brand new, its not going to be some rebuilt painted blue. This motor will have all the latest updates done to it and will be better than what you had, and when you consider that what you had was broken, then this really sounds like a great deal.

I wonder when Porsche is going to get the 996/986 engine right. I think this failure rate is appalling for a Porsche, let alone any other brand. We are talking 2002 engines built after over 5 years to improve the design failing in 10,000 miles here, not much solace for someone who gets a new engine that quality has improved. This may kill the value of the used cars, who wants to buy an off warrantee car with a time bomb engine. <img border="0" alt="[typing]" title="" src="graemlins/yltype.gif" />

Cydog, I just picked up my 2000 C2 from the dealer after having the engine replaced. It had 12,000 miles on it in 3 years. I was not too thrilled, but when I went it to see the mechanic, he showed me the rebuilt engine (which looked absolutely brand new) and said it is just as good as a brand new one. The new engine sounds much smoother than before. After break in we'll see how the power is. Scott

996Scott, what was the issue/reason for your failure and engine change?

They were not exactly sure what the problem was. I have burned 1qt of oil every 5-600 miles since the start with a lot of smoke on start up. Everyone said it was not a big deal. At 6k miles the plugs were bad so they replaced them. Now at 12k miles the plugs were bad again. They narrowed it down to the #4 cylinder, but when they did a leak-down test, they could not find anything too out of the ordinary. Porsche wanted the dealer to tear into the engine to inspect,the dealer said with the history of burning oil, smoke, and bad plugs, the engine should just be replaced. Porsche said no, but then decided to go ahead and do it. That is the story I got. I'm sure yours will be great with the new engine. Good luck. Scott

That really sucks guys.It is really surprising that these stuff are happening. I'm not aware of these stuff happening with the older engines. This puff of smoke that everyone said it was not a big deal and the plug fouling at 6K !!!!...my my how can they say these things??! While Porsche sends a rebuilt engine I suspect that these units are the previously grenaded ones repaired and rebuilt. If I was in your shoes guys I would not accept anything BUT a new engine or a guarantee from porsche that the rebuilt engine had equal or less miles than mine. It reminds me of my insurance guy who wanted to put a used bumper on my 10K mile M3 when i had a fender bender! I told him heck no, there was no way I would accept this on a as new maintained car with so few miles on... Sorry this is ridiculous for you guys that paid what, more than 80K for your cars?

Update: Got a call from the dealer, and PNA will do the swap with a new engine. All in all, a good ending, but I wouldn't jumped for the rebuilt X51.

Oops... the last line should have read "but I would've jumped for the rebuilt X51 engine"

How often are the 996 engines failing? I've never heard of such an issue until this thread...then again, I don't watch the 996 board. Is it usually the same reason for the failure?

My 2002 C2 had the engine replaced at 2000 miles. I had major oil consumption but was never told what was wrong. Car was prefect afterward and was running strong with 27000 miles when I traded for my Turbo

I am tempted at jumping into this watercooled world but those incessant reports of engine failures have been, hmm..., disappointing. I have read somewhere that the reason is the new technique used to make the aluminium engine casing is not bulletproof; ie. they "manage" to inject air bubbles into it and thus the thermal properties are very inconsistant. This translates into engines failing in various ways. I have read failure rates up to 35% at the production. Most of them should be melted down again. I suppose. Anybody heard this as well. Just bogus? Jan

</font><blockquote><font size="1" face="Verdana,Tahoma,Helvetica">quote:</font><hr /><font size="2" face="Verdana,Tahoma,Helvetica">Originally posted by Cupcar: <strong>I wonder when Porsche is going to get the 996/986 engine right. I think this failure rate is appalling for a Porsche, let alone any other brand. We are talking 2002 engines built after over 5 years to improve the design failing in 10,000 miles here, not much solace for someone who gets a new engine that quality has improved. This may kill the value of the used cars, who wants to buy an off warrantee car with a time bomb engine. <img border="0" alt="[typing]" title="" src="graemlins/yltype.gif" /> </strong></font><hr /></blockquote><font size="2" face="Verdana,Tahoma,Helvetica">Ditto... Scares the heck out of me for buying an used 996...