 OT: 2003 Boxster S engine replacement |
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| gandalf_025 |
 Dec 6 2013, 12:25 PM
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#81
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Senior Member  Group: Members Posts: 1,525 Joined: 25-June 09 From: North Shore, Massachusetts Member No.: 10,509 Region Association: North East States  |
I would start by asking the dealership for contact information for the
Porsche Warranty Rep in your area. If Porsche is anything like other Car Manufacturers.. Which I have no idea of.. There should be someone that goes from Dealership to Dealership to OK Warranty work. I would make an appointment to speak to him and discuss the problem. Print out this thread and show him.. You never know what could result from it. Earlier this year, my niece needed a clutch replaced on a Honda Civic Si at 90,000 miles and I asked the dealership to get me in touch with the Honda Warranty Rep. I explained the problem and showed documentation and the parts removed from the car and told him it was a defect, not caused by abuse or neglect. I was calm and pleasant to him and talked to him professionally. The dealership replaced the flywheel, pressure plate and clutch disk which they billed her 1800.00 and after I talked to the Honda Rep.. They refunded all but 450.00 A month ago, the clutch master cylinder started to have an issue and when I went back to the dealership and they realized I was going to go to the Warranty Rep again, they did the job for parts only, no labor. So, 425.00 turned into 200 or so. Bottom line..can't hurt to ask.. Maybe only Honda works like that ? But you never know.. By the way.. anyone know anyone that needs a 2009 Honda Civic SI flywheel and pressure plate cheap ? I have them cluttering up my garage.. |
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| HAM Inc |
Dec 6 2013, 01:27 PM
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#82
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Senior Member Group: Members Posts: 850 Joined: 24-July 06 From: Watkinsville,GA Member No.: 6,499 Region Association: None |
QUOTE(ThePaintedMan @ Dec 6 2013, 09:35 AM)  QUOTE(jesiv @ Dec 6 2013, 11:23 AM) I purchased the car from the dealership with the Porsche CPO and have had it regularly serviced by the dealer. So I will keep my fingers crossed. No really expecting any help but have nothing to lose. Any ideas on the type of argument I should make? Regards James Would the dealership allow you to send the heads to Len at HAM? (IMG:style_emoticons/default/idea.gif) Then they could put everything back together. I have repaired cracked heads for a Porsche dealer. Sent out 2 quotes today to independent shops for M96 crack repair. Would not be a bit surprised to find that a waterpump failure was in their history. |
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| TCallas |
Dec 6 2013, 01:50 PM
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#83
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Newbie Group: Members Posts: 1 Joined: 6-December 13 From: Torrance, CA Member No.: 16,734 Region Association: Southern California |
I have been watching this thread, early on with frustration and then it lead to it being quite humorous. This is my first post to this group because I felt that I had to sign up to add my worthless (to some) information to this thread. It's amazing how human nature is, we don't like or even sometimes don’t believe what we don't understand. Technicians are the worst about this, trust me, I have 5 of them and know their mentality. They fight something to the bitter end, to the last moment because it’s something they have “Never Seen”. Well, sorry to say but there are things that happen in this world that you might never have seen or experienced or even heard of. I have a saying, you don’t know what you don’t know!
I agree, an AOS and Heat Exchanger could possibly cause an intermix issue but the chances are very rare. With the M96/M97engines, it's NEVER a head gasket. Yes, those items need to be eliminated first, but most of the time it ends up being a crack(s) in a cylinder head(s). NO, I don’t like feeding the S#!t sandwich to someone but I honestly believe that they are better off informed that one not. The old saying, ignorance is bliss doesn't apply here. As for the FOD comments, YES, the coolant pump FOD can create hot spots in the cylinder head passages and this will cause cracks. These cracks can and usually lead to oil in the coolant system intermix. Jake is very knowledgeable on the M96/M97 and basically all Porsche engines, when he speaks I recommend people listen. No ass kissing, just the facts people. I might be coming off a bit harsh, I’m sitting in a large room in the Downtown LA Courthouse waiting for Jury Duty, SUCKS to be me, NOT…LOL! Thank You, Tony Callas |
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| ThePaintedMan |
Dec 6 2013, 02:21 PM
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#84
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Advanced Member Group: Members Posts: 3,887 Joined: 6-September 11 From: St. Petersburg, FL Member No.: 13,527 Region Association: South East States 
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James, did you get that? Len Hoffman is HAM Inc, who has weighed in here on the topic a few posts back. He knows his stuff, as witnessed by all the people who send heads to him, including Jake. He'll get it right the first time and for a decent price, from what I understand. One day when I get to finally rebuild a motor, he'll be the guy I'll send stuff to.
Wow, now Tony Callas weighed in here too? This is turning out to be a who's who of engine and maintenance experts - Jake, Woody, Len, Tony. We're in good company gents, and like I said, I'm learning a ton! |
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| jesiv |
Dec 6 2013, 02:22 PM
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#85
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Senior Member Group: Members Posts: 552 Joined: 5-August 07 From: Pensacola/Milton, Florida Member No.: 7,975 Region Association: Northern California |
So what are your thoughts of only doing a top end rebuild on a 97k motor? Is it a fix or a bandaid accelerating a bottom end failure?
Also what are the odds of fod in the case? Regards James |
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| jesiv |
Dec 6 2013, 02:27 PM
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#86
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Senior Member Group: Members Posts: 552 Joined: 5-August 07 From: Pensacola/Milton, Florida Member No.: 7,975 Region Association: Northern California |
George
I sent HAM an email. I am looking forward to his reply Thank you regards James |
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| euro911 |
Dec 6 2013, 02:42 PM
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#87
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Retired & living the dream. God help me if I wake up! Group: Members Posts: 8,937 Joined: 2-December 06 From: So.Cal. & No.AZ (USA) Member No.: 7,300 Region Association: Southern California
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QUOTE(ThePaintedMan @ Dec 6 2013, 01:21 PM) ... Wow, now Tony Callas weighed in here too? This is turning out to be a who's who of engine and maintenance experts - Jake, Woody, Len, Tony. We're in good company gents, and like I said, I'm learning a ton! Didn't know they were there (IMG:style_emoticons/default/confused24.gif)... where Edelweiss Porschaus used to be located - right next door to my orthopedic doctor's office. I'll have to stop in some day (IMG:style_emoticons/default/idea.gif) |
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| Jake Raby |
Dec 6 2013, 04:16 PM
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#88
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Engine Surgeon Group: Members Posts: 9,398 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
Tony and I work together and talk about things all the time in our classes, trying to help people stay out of trouble.
I just couldn't help but tell him about this thread. Perhaps we'll use the material thats been generated here to add to the class a little bit. Attendees love that. Also, another person weighed in here that you guys didn't consider. He just happens to be the most experienced M96 engine builder in the country and possibly the world. I sign his paychecks :-) |
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| HAM Inc |
Dec 6 2013, 04:50 PM
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#89
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Senior Member Group: Members Posts: 850 Joined: 24-July 06 From: Watkinsville,GA Member No.: 6,499 Region Association: None |
If you guys had any idea how many M96/97 engines Jake's company Flat 6 has built it would probably blow your minds. When you debate Jake about issues with these engines keep that in mind.
And also keep in mind that damn near every one that he's built had suffered a failure of some sort. And near as I can tell every failure is the result of some deficiency in either the design or manufacturing process. And some failures are the result of shops incorrect response to some issue, like not chasing down all the blades from a failed WP. The crazy shit we've seen over the years with the M96 would be seriously deflating to Porsche's reputation for excellence if the general motoring public knew. All that said I think they're actually pretty solid lumps once the issues have been corrected. |
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| HAM Inc |
Dec 6 2013, 04:56 PM
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#90
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Senior Member Group: Members Posts: 850 Joined: 24-July 06 From: Watkinsville,GA Member No.: 6,499 Region Association: None |
QUOTE I have a saying, you don’t know what you don’t know! I sometimes lay awake at night wondering what I don't know and worrying about it. One reason I never argue with someone knowledgeable who's telling me something new. |
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| Jake Raby |
Dec 6 2013, 07:27 PM
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#91
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Engine Surgeon Group: Members Posts: 9,398 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
QUOTE If you guys had any idea how many M96/97 engines Jake's company Flat 6 has built it would probably blow your minds. We were doing it well before anyone even knew it, too. Thats the benefit of working in the middle of no where and keeping the place locked down like a military compound :-) Hell, Blake and I built another one M96 this week.. This one was for a slightly different purpose, though… To gain the photos for the step by step assembly portion of my book, "The M96 Definitive Guide" I owe Blake a big favor, he picked up my slack on Sunday and Monday's photo shoots while I was laid up at home with the nastiest case of the stomach flu on the planet. Here's some photos from the shoot :-) This photo was taken about 5 minutes before I started puking my guts up! I was so delirious that I installed the crankshaft into the carrier backward! (IMG:http://www.914world.com/bbs2/uploads_offsite/scontent-b-atl.xx.fbcdn.net-1095-1386379663.1.jpg) Here's the never before released photo of the Patent pending Raby faultless piston pin and clip tool for the M96 engine. (IMG:http://www.914world.com/bbs2/uploads_offsite/scontent-b-atl.xx.fbcdn.net-1095-1386379665.2.jpg) Installing a cylinder head… That was previously cracked onto this 2003 Boxster S engine! Repaired by Len, of course! (IMG:http://www.914world.com/bbs2/uploads_offsite/scontent-b-atl.xx.fbcdn.net-1095-1386379665.3.jpg) Nick Czerula shot over 1500 photos of engine assembly this week, and a couple of me for the book, too. Here's one of them… Nick can make anyone look good! (IMG:http://www.914world.com/bbs2/uploads_offsite/scontent-b-atl.xx.fbcdn.net-1095-1386379666.4.jpg) This post has been edited by Jake Raby: Dec 6 2013, 07:28 PM |
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| Chris Pincetich |
Dec 6 2013, 08:09 PM
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#92
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B-) Group: Members Posts: 2,082 Joined: 3-October 05 From: Point Reyes Station, CA Member No.: 4,907 Region Association: Northern California |
Nice smile Jake! (IMG:style_emoticons/default/beerchug.gif)
For some reason I always imagine that it is 2am in GA and you are getting a sailor jerry tattoo on one arm while typing a reply to our posts with the other arm, snarling and spitting the whole time (IMG:style_emoticons/default/biggrin.gif) Is your shop a potential source for "rebuilt" Boxters? (IMG:style_emoticons/default/shades.gif) Great info in this thread. I'm looking forward to reading about the final resolution. There are lots of used Boxters in the SF Bay area here in CA, and one day one of them will be mine (IMG:style_emoticons/default/happy11.gif) To TCallas (IMG:style_emoticons/default/welcome.png) |
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| Jake Raby |
Dec 6 2013, 08:21 PM
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#93
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Engine Surgeon Group: Members Posts: 9,398 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
QUOTE(ChrisNPDrider @ Dec 6 2013, 06:09 PM) Nice smile Jake! (IMG:style_emoticons/default/beerchug.gif) For some reason I always imagine that it is 2am in GA and you are getting a sailor jerry tattoo on one arm while typing a reply to our posts with the other arm, snarling and spitting the whole time (IMG:style_emoticons/default/biggrin.gif) Is your shop a potential source for "rebuilt" Boxters? (IMG:style_emoticons/default/shades.gif) Great info in this thread. I'm looking forward to reading about the final resolution. There are lots of used Boxters in the SF Bay area here in CA, and one day one of them will be mine (IMG:style_emoticons/default/happy11.gif) To TCallas (IMG:style_emoticons/default/welcome.png) We only develop and build engines here… I do end up with a lot of broken cars that people give up on when those "mythical" engine failures occur. I have an 02 Boxster S now with a cracked head. It came from a dealership in Texas (No joke and I just realized how ironic that is!) and its a solid car :-) I'll sell it cheap, I have these things coming out my ears. Hell had to buy a Mini- Storage facility that was up for sale down the road just so we'd have a place to store them all. This post has been edited by Jake Raby: Dec 6 2013, 08:23 PM |
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| jesiv |
Dec 6 2013, 08:51 PM
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#94
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Senior Member Group: Members Posts: 552 Joined: 5-August 07 From: Pensacola/Milton, Florida Member No.: 7,975 Region Association: Northern California |
I sure wish I still lived in Alabama much closer to Jake than SF California!
Jake thank you for all the info. It gave me enough hope that I told the dealer to proceed with removing the engine and head to see what happened. I have my fingers crossed it is not a blown engine. If it is a cracked head I plan to send it to Ham so he can work his magic. Regards James |
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| Jake Raby |
Dec 6 2013, 09:52 PM
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#95
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Engine Surgeon Group: Members Posts: 9,398 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
I have more M96 powered cars here from California than I do from Georgia. We became shipping brokers just to facilitate shipping cars all over N. America.
The crack on the back side of the head will be hard to find unless Len does the pressure test. |
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| HAM Inc |
Dec 7 2013, 09:34 AM
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#96
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Senior Member Group: Members Posts: 850 Joined: 24-July 06 From: Watkinsville,GA Member No.: 6,499 Region Association: None |
QUOTE Nick Czerula shot over 1500 photos of engine assembly this week, and a couple of me for the book, too. Here's one of them… Nick can make anyone look good! Damn! I need to get one of those lenses! They're magic! (IMG:style_emoticons/default/beerchug.gif) (IMG:http://www.914world.com/bbs2/uploads_offsite/scontent-b-atl.xx.fbcdn.net-1095-1386379666.4.jpg) |
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| HAM Inc |
Dec 7 2013, 10:02 AM
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#97
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Senior Member Group: Members Posts: 850 Joined: 24-July 06 From: Watkinsville,GA Member No.: 6,499 Region Association: None |
Off topic, but thought it worth while since this is at it's heart an aircooled site.
Still a butt load of T4 engines coming off the hill in Cleveland, GA too! These heads are all for one engine batch, and that's not all of them. The complete order wouldn't fit on the cart!  |
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| Jake Raby |
Dec 7 2013, 10:15 AM
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#98
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Engine Surgeon Group: Members Posts: 9,398 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
QUOTE(HAM Inc @ Dec 7 2013, 08:02 AM) Off topic, but thought it worth while since this is at it's heart an aircooled site. Still a butt load of T4 engines coming off the hill in Cleveland, GA too! These heads are all for one engine batch, and that's not all of them. The complete order wouldn't fit on the cart! Yep all kinds of engines being produced at the Mountain Power House! And a 2014 Cayman S just arrived from Isringhausen Porsche. After it receives a Raby 4.2 you can buy it new on the showroom floor at Isringhausen! Just wait till you guys receive your next issue of Panorama and see Cayman X featured:-) We currently have Porsche engines in work spanning from 1956-2014:-) |
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| malcolm2 |
Dec 7 2013, 10:44 AM
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#99
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Advanced Member Group: Members Posts: 2,749 Joined: 31-May 11 From: Nashville Member No.: 13,139 Region Association: South East States
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No similarity to the "bug me" video and at all; the shop, the engine, the man or the tools. (IMG:style_emoticons/default/cool.gif)
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| Jake Raby |
Dec 7 2013, 12:08 PM
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#100
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Engine Surgeon Group: Members Posts: 9,398 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
QUOTE(malcolm2 @ Dec 7 2013, 08:44 AM) No similarity to the "bug me" video and at all; the shop, the engine, the man or the tools. (IMG:style_emoticons/default/cool.gif) But its all been built on the same piece of property and by the same hands. |
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