Rear main seal leaks – This was an issue for earlier models and is more of a cosmetic issue than a performance issue.Oil starvation due to built-in oil sump – The new design of the Boxster’s oil sump had a lower holding capacity, which led to numerous issues.Intermediate shaft bearing failures – After years of use, oil can get past the bearing seal causing pre-mature wear.Engine casting porosity – This should not be an issue as many engines with the problems were replaced under warranty.Unfortunately, normal operation over time leads to cracks in the cylinders. Cracks in the cylinder lining – A new technique was used to incorporate the cylinder liners right in the case.Cracks in the cylinder head – It isn’t the most common issue, but cracks can form at the seats of exhaust valves or the spark plug hole.Chain tensioner failure – An issue for Boxsters that were built prior to 2000.Air-oil separator failure – If the air-oil separator goes out oil can get into the intake and lead to performance issues.Here are some of the most common repairs that we’ve come across: Over the years a number of deficiencies have been identified and fixed in latter versions of the engine.Īt our Austin Porsche repair shop we’ve worked on a number of Boxsters since their release in 1996. However, mechanical endeavors are rarely perfect on the first attempt. Right from the onset, the Porsche Boxster’s M96 engine (and subsequent M97) was developed to offer superior performance and scalability.
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