Two problems related to engine failure have been reported for the 2005 Porsche Boxster. The most recently reported issues are listed below.
Traveling 75mph on freeway when oil & engine lights came on and vehicle simultaneously came to dead stop in traffic; diagnosed as catastrophic engine failure by dealer service mgr. , engine replaced at cost of $17,000+. No prior warning. No fault of my own per svc. Mgr. 38k miles on 2005 vehicle, 3 mo out of warranty. Many similar incidents reported on several web sites. Service mgr reported Porsche well aware of this issue but does nothing because its too costly to repair and prefers to handle on case by case basis. Sometimes covers part of cost, sometimes nothing. Had I not been able to brake and coast to stop, I would have rolled over and most likely been killed! damaged engine returned to Porsche in germany. I have the part that broke from which little balls spewed throughout the engine. I am informed this occurs in approx. 20% of Porsche Boxsters and other Porsche vehicles for several years until they redesigned the bolt in 2010 models. Unable to determine how many injuries and/or deaths resulting from these catastrophic engine failures because accidents would appear to be from driver error and no one would know the engine failed under these circumstances! Porsche employees are instructed not to acknowledge knowing anything about this being an ongoing issue and not to make repairs at Porsche expense except for the customers who raise the biggest fuss. Another Boxster was in the shop at the same time as mine for the same problem. The google address link below shows a photo of a Boxster crankshaft and intermediate shaft. One of the connecting rods broke near the piston wrist pin end and the intermediate shaft is damaged. This catastrophic engine failure is the result 1) a seized connecting rod bearing, 2) a loss of oil pressure, 3) bad original component design, 4) intermediate shaft assembly failure (bolts or mechanical connection weld, crimp). This is what happened to my car. . Read more...
My 2005 Porsche Boxster, 23k mi, had catastrophic engine failure at idle. The engine stalled;I was able to restart but a loud clanging noise came from engine. The car then died again. The mechanic said it was due to an intermediate shaft (ims) failure; the required engine replacement is $14k. The mechanic said he has heard of significant number of ims failures (but Porsche has not notified owners). There were no injuries, but certainly engine failure like this could have serious consequences at freeway speeds. Porsche forums on internet show frequency of failures from this defect (poorly designed bearing assembly on ims) is very high, as much as 8-11% in one forum poll.