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    Blown Engine

    Well guys....after 4 years and 31K my 05 Carrera S engine has self destructed. 

    I took it to dealer this past weekend after I noticed a very slight random knocking noise coming from the engine.  You could only hear the noise at idle or when listening very close to the engine bay.  The dealer now states the knocking noise has become very noticeable and has indicated a complete motor replacement (99%) or rebuild is very likely. 

    I bought an extended warranty which should cover the repairs, but I'm a little disheartened that this has happened so soon....I realize sh*t happens.  

    Anyway, any advice dealing with this situation would be useful.  I'll provide an update once I know more.  Thanks in advance for everyone's time.

     

     

       


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    Sorry to hear that. As long as the extended warranty pays for the repair, I wouldn't worry too much. I'm also pretty sure that your dealer tries to get some money from Porsche first, you never know.  The "rebuilt" engines are as good as new, I wouldn't worry too much.

    Just make sure the work is done by a professional who knows what he's doing.


    --

    RC (Germany) - Rennteam Editor 997 Turbo, Cayenne Turbo S, BMW M3 Cab DKG, Mini Cooper S JCW


    Re: Blown Engine

    yup, as rc stated. if it's done at your OPC your car will be back as new....

    try for them not to get into your pockets. 32k miles/km is nothing.......


    --
    Speed has never killed anyone, suddenly becoming stationary... That's what gets you.

    Re: Blown Engine

    Since there is an extended warranty, the owner wouldn't pay. I presume it is Intermediate Shaft Failure, a known problem with these engines. I know of at least one case on a 996 that Porsche replaced the engine FOC after 3 1/2 years.

    On the new DFI engines there is no Intermediate Shaft, which says a lot!


    --
    It's not where you're going, it's how you get there that counts

    Re: Blown Engine

    that's what i heard as well. porsche are very generous when it comes to engine failure.....after all it's the heart and soul. and they'd rather throw in a free engine than possibly face bad press.


    --
    Speed has never killed anyone, suddenly becoming stationary... That's what gets you.

    Re: Blown Engine

    Sorry to hear this. I'm glad you have an extended warranty so no financial pain. But it isn't a nice thing to happen when you spend so much on a car. Unfortunately, you will need to go through engine break-in again 


    --

    Rennteam Moderator - 997S GT Silver/Cocoa, -20mm/LSD, PSE, SportDesign rims, Zuffenhausen collection


    Re: Blown Engine

    Talked last weekend to a person who's had an engine breakdown too. At 156.000km.

    He had to pay for himself altough porsche stated that the engine didn't overrev or showed any signs of misuse.Smiley


    --

    ex 965 3.3turbo/ ex 993 targa / ex 996 cab /

    now 997S cabrio //  Audi A5 S-line 3.0tdi Quattro


    Re: Blown Engine

    cmon  tell us  the truth!

     

    what the h3LL   you did  to broke an engine with  only 32 k miles!!

     

    overreved?    very  very rare.


    Re: Blown Engine

    xandi911, I have never tracked or abused the car outside of normal spirited driving.  This purchase is a one shot deal for me...meaning I am planning to keep the car for an extended period of time. I was trying to maintain very good care.....unfortunately something broke and I hope to find out the cause in the next day or two.  Engine diagnostics showed no overrevs or anything abnormal. Google certianly shows numerous hits on Intermediate Shaft Failures for engines of this type and mileage.


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    911Fanatic:

    xandi911, I have never tracked or abused the car outside of normal spirited driving.  This purchase is a one shot deal for me...meaning I am planning to keep the car for an extended period of time. I was trying to maintain very good care.....unfortunately something broke and I hope to find out the cause in the next day or two.  Engine diagnostics showed no overrevs or anything abnormal. Google certianly shows numerous hits on Intermediate Shaft Failures for engines of this type and mileage.


    ok  i believe in you!

     

    but  i had a CS  and  its engine   seems to be like a stone!     there are another historics like  this??


    Re: Blown Engine

    All,

    I received an update from the dealership today.....the engine failure was due to an Intermediate Shaft Bearing failure.  Three (3) bearings fell into the motor causing the random knocking noise and metal shavings to be throughout.  It appears a complete engine replacement is in order....hopefully one with the newer core (2005+) and updated design that resolves all these issues.

    See the attached link for additional details regarding this issue: http://www.lnengineering.com/ims.html

    It will be interesting to see how the warranty company (Fidelity) works through this claim.

     

     


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    Yes, as predicted IS was the culprit. Smiley

    Good luck with the warranty claim.

     


    --
    It's not where you're going, it's how you get there that counts

    Re: Blown Engine

    a sad site  SmileyEngine Failure 001.jpg


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    2005 Black 997 Carrera S

    Re: Blown Engine

    Engine Failure 008.jpg


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    the culprit Smiley

    Engine Failure 007.jpg


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    Engine Failure 010.jpg

    Engine Failure 011.jpg


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    911Famatic, sorry to hear of the reliability issues, but I love the engine pics!  


    Re: Blown Engine

    Love the pics too. Real life stuff !! Hope alll will be like new , soon


    --
     997.2 C2S, PDK, -20mm

    Re: Blown Engine

    These exchange engines are not brand new, are they?

    I think they are remanufctured using any upgraded parts that might have come out since. I am not 100% sure though. 


    --
    It's not where you're going, it's how you get there that counts

    Re: Blown Engine

    yes, replacement engines are "rebuilt" engines but with the same design as the original.


    --

    Re: Blown Engine

    Carlos from Spain:

    yes, replacement engines are "rebuilt" engines but with the same design as the original.

    Thanks!


    --
    It's not where you're going, it's how you get there that counts

    Re: Blown Engine

    Thanks for the interesting pics!

    Is there any difference in the frequency of I/S problems on 3.8 vs 3.6 engines?

     


    Re: Blown Engine

    Not really, the design of original 986 to 997.1 engines is the same.

    Except of course the GT3/GT2/Turbothat have a  totally different engine.

    997.2 and 987.2 (except 2.9) engines don't have a I/S.


    --
    It's not where you're going, it's how you get there that counts

    Re: Blown Engine

    My dealer stated that Porsche redesiged the IMS bearing and hub flange in 2006 engines to help with IMS reliability issues.  This is a key point that I will be investigating as I move forward.  I don't want to be faced with a similiar issue when I hit 30K again!      


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    Just found out from dealer that my engine will be replaced free of charge less my deductible ($100). Smiley  Should have my car back by Friday of this week.  I'll take some pictures of new motor for those that are interested and post later this week.  Dealer also confirmed that IMS bearing and IMS hub flange will be of new design, I'll inspect evidence to make sure.  Existing air conditioner, power steering and alternater will be transferred, everything else will be new/refurbished.


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    911Fanatic:

    Just found out from dealer that my engine will be replaced free of charge less my deductible ($100). Smiley  Should have my car back by Friday of this week.  I'll take some pictures of new motor for those that are interested and post later this week.  Dealer also confirmed that IMS bearing and IMS hub flange will be of new design, I'll inspect evidence to make sure.  Existing air conditioner, power steering and alternater will be transferred, everything else will be new/refurbished.

    All's well that ends well.  Smiley


    --

    fritz


    Re: Blown Engine

    great news


    --

    Re: Blown Engine

    My new engine finally arrived. Smiley  The only item transferred from old motor to new was the A/C, everything else is either new or refurbished.

    1241874096184DSC_0014.JPG

     

     


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    I also confirmed that the Intermediate Shaft Bearing was redesigned.  The bolt/stud is much bigger than what was in the original motor (see example on the right).  The new bearing is also a double row bearing vs. single row.

    1241875353680DSC_0001.JPG

     


    --
    2005 Black 997 Carrera S

    Re: Blown Engine

    Picture of failed single row bearing....

    DSC_0003.JPG


    --
    2005 Black 997 Carrera S

     
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