Fortunately, the aftermarket has heavy duty billet parts to solve the problem. LN Engineering comes to the rescue yet again with the billet parts pictured here.
Usually, this is noticed when puffs of smoke are seen when the car is being driven hard. Sometimes oil can accumulate inside the unit and the engine can suddenly suck in a large amount of oil. An amount large enough to hydrolock the engine and destroy rods and pistons!
The cure for this wonderful issue is to replace the air oil separator every 3 years or so whether the car needs it at the time or not.
So, to make your 911, Boxter or Cayman reliable with an M96, or even if you are rebuilding a tired M97, you only need to use heavy-duty IMS shaft bearings, Nikasil cylinder liners, forged pistons and racing rods, deep sump oil pan and baffles, billet timing chain tensioner shoes, improved rear main seals, water pump and air oil separator. You should do all of these things when rebuilding the improved M97 as well, just in case because it has a lot of the same stupid engineering, just debugged more.
Do all this and pay scrupulous attention to all clearances and tolerances including some that you might not ever think of checking that requires some imagination to measure and no way to correct if they are off. Replace stuff with lots of brand new genuine expensive OEM Porsche if anything is off or pay the piper. Oh yeah, be sure you install those wrist pins correctly!
If everything is right, with a bit of luck, you will have a really reliable, mild street and track car! Ugh.
Looking at the nice used early 996 911 or 986 Boxster that is amazingly cheap on Craigslist? Turn around and run away fast! Can anyone say Pandora’s box? Want a project to end all projects? It can be fixed well if you are smart, coordinated and don’t cut corners. If that doesn’t scare you away, you can get a bargain on a used Porsche. There is a huge aftermarket to correct almost all of these issues.
If any of you readers have other lame performance car engines you would like us to cover, let us know in the comments below! Yes, we know the Mazda 13B-REW is one and we will probably do something about that. How about less well known automotive disasters?