2001 Porsche 911 Turbo

On April 26, 2013, the Office of Defects Investigation (ODI) opened PE13-009 to investigate 10 complaints alleging incidents of sudden coolant loss while traveling on public roadways in certain model year (MY) 2001 through 2007 Porsche 911 vehicles.The complaints alleged that pipe ends joined by epoxy to certain cooling system components may fail suddenly and separate, resulting in large volumes of coolant leakage.The investigation was opened to assess evidence of a design or manufacturing defect in the coolant pipe fittings and any related safety consequences. In response to ODI?s Information Request letter, Porsche identified a manufacturing quality issue with the supplier?s application of adhesive to coolant pipe fittings that resulted in elevated failure rates in approximately 6,800 early production 997 generation vehicles (MY 2007 and early MY 2008).ODI?s analysis of field data showed that the age-adjusted failure rate for these vehicles was approximately six times greater than MY 2001 through 2005 996 generation vehicles and MY 2008 through 2011 997 generation vehicles built after a process improvement for adhesive application was implemented by the supplier.Most of the leak complaints reviewed by ODI did not appear to involve complete separation of the fittings and many were detected when the vehicle was parked.There were no crashes or injuries reported to be related to the alleged defect in any of the subject vehicles.ODI identified two allegations that coolant leakage resulted in loss of control incidents, but neither involved vehicles affected by the assembly process quality issue.A third loss of control allegation involving a vehicle built during the period affected by the supplier process concern is not counted since ODI was unable to contact the owner to confirm the incident.See the full closing resume in the document file for PE13-009 for additional information about the subject cooling system and ODI?s analysis of field data related to the alleged defect. A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.

COOLANT PIPE EXPERIENCED CATASTROPHIC FAILURE WHILE ON A PUBLIC ROADWAY. WAS TRAVELING ON STRAIGHT, SMOOTH ROAD ABOUT 55-60MPH WHEN COOLANT WARNING LIGHT CAME ON AND ENGINE TEMPERATURE ROSE WITHOUT WARNING. I HAD NO WHERE TO PULL OVER ON THE TWO-LANE ROAD, SO WAS FORCED TO STOP CAR IN LANE, PUTTING MYSELF AND FAMILY AT RISK OF BEING HIT BY TRAFFIC WHILE WE WAITED 4 HOURS FOR A TOW.

NHTSA ID

11023348

Incident

Sep 11, 2017

Mileage

59,000 mi

COOLANT PIPES COME APART WHILE DRIVING AND THERE WAS RAPID LOSS OF ENGINE COOLANT. THE PROBLEM EXISTS ON THE GT1 MOTOR BECAUSE THERE ARE A COUPLE COOLANT PIPES IN THESE MOTORS THAT ARE NOT A SINGLE CAST PIECE: THE LARGER CAST PIECES HAVE EXTRUDED INLET/OUTLET TUBES THAT ARE CONNECTED USING AN ADHESIVE. THERE IS NO METAL-TO-METAL FRICTION OR PRESS-FIT TO KEEP THESE TUBES IN PLACE, SO AFTER ENOUGH HEAT CYCLES THE ADHESIVE WILL SOFTEN/LOOSEN UP AND THE TUBE WILL COME OUT OF THE CAST BLOCK (WITH THE HOSE STILL ATTACHED), RESULTING IN A RAPID LOSS OF ENGINE COOLANT. ....UPDATED 04/25/16 *BF

NHTSA ID

10716256

Incident

Mar 18, 2015

Mileage

118,800 mi

WHILE DRIVING ON THE HIGHWAY A CATASTROPHIC FAILURE OCCURRED IN THE COOLANT SYSTEM. ONE OF THE ALUMINUM HOSE FITTINGS THAT IS EPOXIED INTO THE ALUMINUM HOUSING BROKE FREE CAUSING ENGINE COOLANT TO EMPTY OUT OF THE ENGINE ONTO THE HIGHWAY IN A MATTER OF SECONDS. THE RUBBER HOSE DID NOT FAIL AND IT WAS STILL CONNECTED TO ALUMINUM HOSE FITTING THAT BROKE AWAY FROM THE HOUSING. I PULLED THE CAR OFF THE FREEWAY IMMEDIATELY TO PREVENT FURTHER DAMAGE TO THE CAR. FURTHER INSPECTION AT THE DEALER SERVICE CENTER SHOWED THERE WAS VERY LITTLE TO NO COOLANT LEFT IN THE ENTIRE SYSTEM. *TR

NHTSA ID

10525577

Incident

Jun 27, 2013

Mileage

62,612 mi

PRESS FIT GLUED COOLANT PIPE FITTING FAILED ? COOLANT COVERED ENGINE AND REAR TIRES. *TR

NHTSA ID

10524591

Incident

Feb 3, 2013

Mileage

22,342 mi

I WAS DRIVING ALONG THE HIGHWAY AT 65MPH AND I NOTICED THAT THE TEMPERATURE GAUGE STARTED INCREASING AND THAT THERE WAS STEAM BELLOWING OUT OF THE ENGINE. PULLED OFF HIGHWAY AND CAR WAS POURING OUT COOLANT FROM THE ENGINE COMPARTMENT - HAD CAR TOWED TO DEALER TO INSPECT. CAR WAS DIAGNOSED WITH EPOXY COOLANT PIPE FAILURE WHERE THE EPOXY HAD FAILED TO KEEP COOLANT PIPE IN PLACE. *TR

NHTSA ID

10515907

Incident

Jun 8, 2013

Mileage

72,857 mi

I HAVE BEEN INFORMED BY MY PORSCHE TECHNICIAN THAT PORSCHE USED AN INFERIOR AND MECHANICALLY POOR DESIGN FOR THE ENGINE COOLANT LINES. THEY ARE GLUED TOGETHER IN A PLACE WHERE THEY GET HOT. AFTER SEVERAL HEAT CYCLES, THEY WILL FAIL. ALL CARS WITH THIS ENGINE DESIGN WILL HAVE THIS FAILURE OVER TIME. IF THE COOLANT LINES FAIL WHILE THE CAR IS MOVING, THE SLICK COOLANT CAN GET ON THE TIRES AND CAUSE AN ACCIDENT. ALSO, THE ENGINE CAN OVERHEAT WITH A REPLACEMENT COST OF OVER $20,000. PORSCHE IS AWARE OF THIS, AS THEY HAVE USED A SUPERIOR THREADED DESIGN ON THEIR RACE CARS WITH THIS ENGINE. I HAVE BEEN ADVISED THAT THIS WILL TAKE THOUSANDS OF DOLLARS TO FIX, AND THE CAR WILL BE OUT OF SERVICE FOR WEEKS. *TR

NHTSA ID

10514700

Incident

May 9, 2012

Mileage

45,000 mi

MY MECHANIC INFORMED ME THAT PORSCHE USED AN INFERIOR AND MECHANICALLY POOR DESIGN FOR THE ENGINE COOLANT LINES. THEY ARE GLUED TOGETHER IN A PLACE WHERE THEY GET HOT. AFTER SEVERAL HEAT CYCLES, THEY WILL FAIL. ALL CARS WITH THIS ENGINE DESIGN WILL HAVE THIS FAILURE OVER TIME. IF THE COOLANT LINES FAIL WHILE THE CAR IS MOVING, THE SLICK COOLANT CAN GET ON THE TIRES AND CAUSE AN ACCIDENT. ALSO, THE ENGINE CAN OVERHEAT WITH A REPLACEMENT COST OF OVER $20,000. PORSCHE IS AWARE OF THIS, AS THEY HAVE USES A SUPERIOR THREADED DESIGN ON THEIR RACE CARS WITH THIS ENGINE. I HAVE BEEN ADVISED THAT THIS WILL TAKE THOUSANDS OF DOLLARS TO FIX, AND THE CAR WILL BE OUT OF SERVICE FOR WEEKS. *TR

NHTSA ID

10514698

Incident

Jun 8, 2011

Mileage

48,000 mi

I WAS ACCELERATING UP TO HIGHWAY SPEEDS (65 MPH) ON A ON RAMP WHEN I HEARD A POP UNDER THE CAR. I FELT THE CAR SHAKE AND DECIDED TO PULL OVER. I DISCOVERED COOLANT LEAKING FROM UNDER THE CAR AND THE SHAKE WAS CAUSED BY MY REAR TIRES SLIPPING AND TRACTION CONTROL COMPENSATING FOR ACCELERATION UNDER SLIPPERY CONDITIONS. LUCKILY I DIDN'T LOOSE CONTROL AND CRASH INTO ANOTHER PERSON THAT MAY HAVE CAUSED INJURY OR DEATH TO THEM OR MYSELF. THE COOLANT PIPING IS A WELL KNOWN PROBLEM WITH THIS YEAR MODEL CAR, IT IS ONLY SECURED BY A GLUE LIKE SUBSTANCE NOT CLAMPED, IT SEEM THE GLUE LET GO AND CAUSED A PRESSURE RELEASE IN MY COOLANT SYSTEM. *TR

NHTSA ID

10511600

Incident

Feb 12, 2012

Mileage

39,700 mi

Parts information for parts withdrawal involving the glass roof - 9J0877069BY & 9J0877069CY. The vehicles affected are ones that use the part numbers mentioned.

Parts information for parts withdrawal involving the door lock. part numbers 9Y0839015, 9Y0839016, 9Y0839016A, 9Y0839015A, 9Y0839015B, 9Y0839016B. Vehicles affected are cars that use the part numbers mentioned.

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Instructions on advanced technical information for paint thickness or decals affecting corner radar sensor operation. Affects all model lines

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