981 Engine / Exhaust - Note Change

[fasterthanlight]

My 981 Boxster S is 2.5 years old and has so far covered just over 11,000 miles. So far there have been no problems of note and it had its first scheduled service at the Porsche dealer in Solihull last summer.

Since just before Christmas I noticed that the sound of the car on start up seems to have changed, sounding slightly more gruff, and subtly less pleasant. I'm certain that this initially occurred after the car had stood for 2 weeks, as I'd been unable to use it. Thinking that some "cobwebs" just needed to be blown away I didn't think too much of it. However, here I am a couple of months later and it's still making the same sound, and if anything, slightly worse. There are no unusual engine temperatures or warning lights / messages on the dashboard. Engine oil level is normal.

I am hoping it could be an exhaust gasket that's failed and nothing more serious, like the engine or the Sports Exhaust (which I doubt would be covered by the 3 year warranty). I'll be calling the dealer tomorrow to get it booked in for an inspection.

 

[CLIFFWILKINS]

After a few miles on the clock the exhaust note can harden making it more of a gruff bark but I would get it checked out by your OPC to be on the safe side.

 

[AndyKerr]

Hi Paul. I live in Redditch and bought my GTS at PC Solihull as well but don't think I've seen your car around the place. Perhaps our paths will cross one day soon...

Can't say I've noticed any change in mine I have to say, but hey ho!

PCS are brilliant and should get it sorted for you. Just ask for Lucy and tell her Andy Kerr said to say hello. []

 

[fasterthanlight]

Well if it's the grey one that I occasionally see in the train station car park as I disembark of an evening, then I've seen you, Andy! Very nice car. I don't park there as I walk to the station.
I've only had excellent service from PCS so far, so I am really hoping they can get to the bottom of my issue. Booked in for this coming Thursday, so will report after then.

 

[AndyKerr]

Well if it's the grey one that I occasionally see in the train station car park as I disembark of an evening, then I've seen you, Andy! Very nice car. I don't park there as I walk to the station.
I've only had excellent service from PCS so far, so I am really hoping they can get to the bottom of my issue. Booked in for this coming Thursday, so will report after then.

That's the one. [] I don't actually park there myself. I'm invariably waiting to meet Mrs. K off the train (I took early retirement some years ago on health grounds and these days live a fairly stress-free life). Next time you're passing feel free to pop over and say hello.

Hope you get it sorted.

 

[fasterthanlight]

Well the OPC has confirmed that the exhaust is indeed blowing. From what I understand this is due to corrosion at the connection between the silencer section of the exhaust and the manifold, which you can easily see through the wheel on the passenger side, although it's more hidden on the driver's side as the connection flanges seem to be orientated slightly differently.

I wish I'd had time to see the car on the ramp to speak to the technician, as both look okay to me, but apparently the corrosion has caused the gasket at the join to fail and hence the blowing. Hoping that this won't be a regular thing for each side of the Sports exhaust, as the car's only done less than 12,000 miles.

Anyway, back to the OPC in a couple of weeks to get it sorted and to get that Porsche soundtrack back.

 

[fasterthanlight]

A further bit of digging with the OPC regarding the repair work that is to be undertaken has revealed that not only is one of the gaskets between the exhaust and manifold in need of replacement, but also the flap inside the sports exhaust is stuck open. You'd think that the sports exhaust flap being stuck open would be heaven, but for whatever reason, it's not producing a great sound. On the plus side, this means that the silencer on that side of the exhaust system will be replaced under warranty.

I don't know about most people, but I turn my sports exhaust on for most driving. Long slogs up the motorway are the only time that I am ever tempted to turn it off to minimise any drone. I might be less tempted to switch it on in future if it's going to cause this problem periodically.

 

[fasterthanlight]

Just to close out this issue, the replacement of the right hand side of the sports exhaust system has been undertaken by the OPC and the car is now making a decent sound. What's interesting perhaps is that there is now a more noticeable change in sound when the sports exhaust is activated, even at lower engine speeds. This suggests that there has always been some kind of fault with my car's exhaust, as even when the car was brand new, the sports exhaust only seemed to be particularly effective at higher revs. No matter, the result is it's been fixed AND improved, so I can get back to enjoying driving it.

 

[rich mich]

this is quite common on boxsters my 987 needed all 6 bolts replaced,with the heating and cooling of the exhaust and the position of the bolts/nuts they will rust away,i changed all 6 myself on my 987 as the opc wanted £500.looking on my 981 there are only 2 bolts a side (the 987 has 3 a side see picture) I changed these when my 987 was 10 years old 37000 miles.my 981 bolts have started to rust away ,luckily my car has a opc warranty and is due its 4 year service next month I shall ask if I can have the bolts/nuts replaced under warranty ,my car as also done 12000 miles