Asantha de Silva

Hi everyone

Hearing some rattling noises on the left intake i took my 15 Boxster S to Porsche to get it checked
After some investigating they found out that 3 of the manifold bots were missing and now want to charge me $1300 under CPO warranty - saying that missing parts aren't covered!!!

I have never touched the manifold nor any workshop i believe , the last time a workshop has worked on it was

1. Porsche - replacing leaking radiator reservoir tank
2. 3rd party - replacing battery, brake fluid flush, replacing spark plugs

Do these bolts come loose all the time? any help appreciated

KBell

I have never heard of this.

Usually people have the opposite problem: difficult to remove.
With heat cycles, salt, and any corrosion, the bolts can be a challenge to get out.

TMc993

If your CPO warranty document confirmed that everything was up to spec when you purchased the car, this is on Porsche. Also, $1300 for three bolts? Bullshirt!!!

tomekz

that might be more common than people think. My 14 Cayman S came back from a PPI at 17k with one of those bolts missing too.

Asantha de Silva

CPO was close to 3 years ago , i have 1 month left on CPO

I find it crazy that they won't honor the CPO for something like this

I guess ill just do the repair on my own - how hard is it to replace the bolts + gaskets anyways .. zzz

burnergt4

Manifold gasket is part no. 997-111-107-31 (approx. $20-26 each), and the screws are part no. 999-073-535-01 (approx. $1.20-2.00 each); torque value for "Exhaust manifold to cylinder head" from the workshop manual is 30 Nm (22 ft. lb.). Here's the tightening sequence:




So if you've got access to a lift and a spare weekend afternoon, this is certainly something that can be done at home.

Asantha de Silva

Thank you so much !! this will definitely come in handy

zedcat

To be clear, you're talking about the exhaust manifold bolts, correct? I've had this happen on 2 9A1 engines- 987.2 and 981. They were just loose on the 987.2 and one was missing and several loose on the 981. have heard of others with the same problem. on the 987.2 I got the torque spec from the dealer and tightened them to spec myself. on the 981 the dealer replaced and torqued them all no charge and no questions asked. That price quote is ridiculous and it seems to me that should be covered. best of luck

Snip's

The OP said intake manifold bolts, not exhaust header bolts....

burnergt4

Oh I missed that entirely—I've had this happen with exhaust manifold bolts, which is why I jumped to that conclusion. But you're right, he did say intake. If that's truly the case, the screw is part no. 900-385-270-01 (6 are used on each side, less than $1 each), and gaskets are 9A1-110-215-01 (3 are used on each side, approx. $5 each). Torque value for “Intake-air distributor to cylinder head” is 13 Nm (9.5 ft. lb.). Here's the tightening sequence for that:




If it really is intake, the Boxster requires a fair amount of interior trim disassembly to get at the engine bay. Here's a video from @TDS on the subject:

Asantha de Silva

Hello everyone - i feel like i cheated everyone with giving the wrong information provided by the person on the phone - looks like it is the exhaust manifold!

here is the report,





Thank you all

burnergt4

Definitely easier than the intake in terms of having to remove trim to get at things. If you plug in the part numbers from my previous post into any of the online parts dealers (Byers Porsche, Delaware Porsche, Sunset Porsche, etc.), you should be able to order them to your door. I prefer Delaware Porsche since they don't charge you sales tax.

Here’s a link to the workshop manual. Search “WM 261019” for the bit on removing and installing the exhaust manifold.

Asantha de Silva

thank you so much - ill give this a try - i did the serpent belt on my own so maybe this shouldn't be too hard .. i hope ..

ICNU

The fact that its the exhaust manifold bolts instead of intake makes the price they quoted you even more insane! This is not a difficult problem to resolve since all they have to do is lift the car. At least the intake manifold requires a lot interior trim to be removed to access the engine cover, but even that is a 30 minute process when you know what you are doing.

MrMoose

I'm glad you posted this. I just checked on my 2010 987.2 and at least four of the exhaust manifold bolts were loose, one very much so!