2002 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.

FROM A STOP I ACCELERATED IN A STRAIGHT LINE ONTO A FREEWAY ON-RAMP. APPROXIMATELY 10 SECONDS LATER I NOTICED A SQUEALING SOUND FROM THE ENGINE BELTS. I LOOKED IN THE REAR VIEW MIRROR AND NOTICED A LARGE VOLUME OF STEAM COMING FROM THE REAR OF THE CAR. HAVING READ ABOUT OTHER PEOPLES EXPERIENCES WITH THIS ISSUE I IMMEDIATELY EXITED THE FREEWAY AS SOON AS I WAS ABLE, STOPPED THE CAR, AND TURNED IT OFF TO PREVENT FURTHER DAMAGE AS ALL COOLANT HAD EXITED THE VEHICLE.

NHTSA ID

10795267

Incident

Mar 7, 2015

Mileage

49,300 mi

THE CAR WAS BEING DRIVEN UNDER NORMAL CIRCUMSTANCES. I HAD CATASTROPHIC COOLANT FAILURE. A HOSE ON MY COOLANT SYSTEM POPPED OFF WHILE DRIVING CAUSING ALL OF THE COOLANT TO GUSH OUT OF THE BOTTOM OF THE CAR, THE CAR DID SLIP A BIT I WAS ABLE TO REGAIN CONTROL AND PULL TO THE SIDE OF THE ROAD. IT SOUNDS LIKE THIS ISSUE HAPPENS TO 911 TURBO'S OFTEN DUE TO THE FACT THAT 8 HOSES WERE ATTACHED ONLY WITH A GLUE THAT CAN GIVE OUT AT ANY TIME. MY LOCAL PORSCHE SHOP WANTS $3000 TO DROP THE MOTOR AND REPAIR/FIX THE 8 HOSES. FROM MY READING ONLINE THIS ISSUE HAPPENS OFTEN TO THIS MOTOR IN CARS FROM 2001-2013. *TR

NHTSA ID

10558119

Incident

Dec 23, 2013

Mileage

35,798 mi

ON TWO SEPARATE OCCASIONS, THE COOLANT FITTINGS WHICH MOUNT IN THE CYLINDER HEAD POPPED OUT. THE FITTINGS ATTACH TO THE COOLANT HOSES. IN BOTH CASES THE EPOXY THAT HELD THE FITTINGS IN HAD FAILED. EACH TIME I WAS DRIVING AND COOLANT SPEWED ALL OVER THE INSIDE OF THE ENGINE BAY AND THEN SUBSEQUENTLY ONTO THE ROAD AS I WAS DRIVING. THE FIRST INCIDENT I WAS DRIVING ABOUT 50 MPH (10/19/11 - 52230 MILES ON THE ODOMETER). WHEN THIS FIRST FITTING POPPED OUT, SINCE IT WAS BEHIND THE ALTERNATOR, DAMAGED IT REQUIRING REPLACEMENT OF THE ALTERNATOR. I HAD TO PAY FOR THE ALTERNATOR AND EPOXIED THAT FITTING OUT. THE SECOND FITTING FAILED ON JUNE 14, 2012 WITH 56384 MILES ON THE ODOMETER. THIS TIME IT WAS IN A LOCATION THAT REQUIRED REMOVAL OF THE ENGINE. THE CIRCUMSTANCES WERE SIMILAR TO THE FIRST, AROUND 50 MPH AND COOLANT DUMPING OVER ALL OVER THE GROUND. SINCE THIS HAPPENED A SECOND TIME, THE SHOP I TOOK THE CAR TO REMOVED ALL 8 OF THE COOLANT FITTINGS IN THE ENGINE, REMOVED THE EPOXY, AND THEN WELDED THEM INTO PLACE. AFTER TWO OF THE FITTINGS POPPED OUT, I WAS NOT GOING TO TAKE ANY CHANCES OF ANOTHER FITTING POPPING OUT AND BEING LEFT STRANDED YET AGAIN. *TR

NHTSA ID

10522635

Incident

Oct 19, 2011

Mileage

52,230 mi

WAS TRAVELING ON FREE ENTRY RAMP, AND AS I ENTERED THE FREEWAY AND APPROXIMATELY 60 MPH, THE CAR EXHIBITED A BRIEF SHUDDER AT WHICH TIME THE CHECK ENGINE LIGHT APPEARED AND BEGAN TO BLINK. I NOTICED A VISIBLE WHITE CLOUD OF SMOKE BEHIND THE CAR. THE CHECK ENGINE LIGHT BLINKED FOR APPROXIMATELY 10-15 SECONDS AND THEN REMAINED OFF. I ALSO NOTICED THE TEMPERATURE GAUGE ROSE ABOVE 180F, WHICH IS THE APPROXIMATE OPERATING TEMPERATURE PER THE TEMPERATURE GAUGE. THE GAUGE HELD SLIGHTLY ABOVE 180F (~5 MM PAST 180F) FOR THE DURATION OF THE DRIVE, ! 5 MILES BEFORE I STOPPED THE CAR AT MY NEXT DESTINATION POINT. UPON TURNING THE IGNITION OFF AND EXITING THE CAR THERE WAS A DISTINCT ANTIFREEZE SMELL. THE CAR WAS OFF FOR APPROXIMATELY 10 MINUTES AND WHEN I RETURNED TO THE CAR THERE WAS A PUDDLE OF ANTIFREEZE DIRECTLY BELOW THE CAR JUST INSIDE THE REAR DRIVER SIDE TIRE. I ESTIMATE APPROXIMATELY 1-2 PINTS OF FLUID. UPON DRIVING THE CAR TO MY FINAL DESTINATION (PERSONAL RESIDENCE) THE TEMPERATURE GAUGE REMAINED ABOVE 180F (! 5-10 MM). DURING THIS SHORT DRIVE, ~ 5 MILES, I TURNED THE CAR'S INTERIOR HEAT TO MAXIMUM TO HELP REMOVE HEAT FROM THE ENGINE. UPON TURNING THE OFF THE IGNITION THE CAR CONTINUED TO LEAK ANTIFREEZE. UPON FURTHER INSPECTION THE ANTIFREEZE APPEARED TO BE LEAKING AT THE CONNECTION TO THE WATER PUMP, ON THE BOTTOM OF THE CAR JUST BEHIND THE EXHAUST, ON THE DRIVER SIDE OF THE CAR. IT IS POSSIBLE IT WAS LEAKING FROM OTHER LOCATIONS BUT I COULD NOT MAKE THIS DETERMINATION WITHOUT PUTTING THE CAR ONTO A LIFT. THE CAR CONTINUED TO LEAK COOLANT AT A SMALL RATE, ESTIMATED TO BE 20-30 DRIPS PER MINUTES. THIS DRIP RATE REMAINED CONSISTENT. THE CAR WILL BE TAKE TO AN INDEPENDENT PORSCHE SERVICE SHOP FOR FURTHER INSPECTION. I AM AWARE THIS IS AN ISSUE ON MANY PORSCHE 911 MODEL CARS AND AM AWARE THE NHTSA MAY BE INVESTIGATING THIS ISSUE FURTHER. *TR

NHTSA ID

10511586

Incident

May 12, 2013

Mileage

85,255 mi

CATASTROPHIC LOSS OF COOLANT DUE TO COOLANT FITTINGS POPPING OUT. LOW SPEED, STRAIGHT LINE DRIVING AT THE TIME SO THERE WAS NO EXCURSION, HOWEVER REAR TIRES WERE SERIOUSLY WETTED AND IF I HAD BEEN IN DIFFERENT CIRCUMSTANCES IT COULD HAVE CAUSED VEHICLE/PROPERTY DAMAGE AND/OR PERSONAL INJURY. *TR

NHTSA ID

10510206

Incident

Mar 16, 2013

Mileage

34,000 mi

OVER TIME I NOTICED A COOLANT SMELL FROM THE CAR WHENEVER I WOULD DRIVE IT WITH THE WINDOWS DOWN, ESPECIALLY WHEN THE CAR WAS IN STOP AND GO TRAFFIC. I THEN NOTICED A SMALL PUDDLE OF FLUID UNDER THE ENGINE AFTER THE CAR WAS PARKED. I TOOK THE CAR TO THE SERVICE AND WAS TOLD THE COOLANT PIPE ON THE ENGINE WAS LOOSE AND COOLANT WAS BEGINNING TO DRIP FROM THE JUNCTION WHERE THE PIPE ATTACHES TO THE ENGINE BLOCK. AFTER SOME INTERNET RESEARCH, I LEARNED THAT THE COOLANT PIPES ARE GLUED INTO THE ENGINE BLOCK AND OVER TIME THERE IS A TENDENCY FOR THE GLUE TO DETERIORATE AND THE PIPES TO COME LOOSE IN TURN CAUSING A MAJOR COOLANT LEAK IN THE AREA OF THE ENGINE AND REAR TIRES. IF COOLANT WERE TO LEAK ONTO THE REAR TIRES, THIS COULD CAUSE A MAJOR ACCIDENT DUE TO LOSS OF TRACTION OF THE REAR TIRES LEADING TO LOSS OF CONTROL OF THE VEHICLE. I ELECTED TO HAVE THE ENGINE REMOVED AND ALL 8 THE COOLANT PIPES PERMANENTLY WELDED INSTEAD OF GLUED AS THIS IS THE ONLY PERMANENT AND SAFE SOLUTION. I AM APPALLED THAT PORSCHE WOULD CHOOSE TO GLUE COOLANT FITTING ON THE ENGINE WHEN A FAILURE COULD CAUSE AND ACCIDENT. *TR

NHTSA ID

10510189

Incident

Jul 16, 2012

Mileage

36,645 mi

AFTER A ROUTINE DRIVE AFTER AN OIL CHANGE SERVICE A LARGE AMOUNT OF COOLANT SPILLED OUT FROM UNDERNEATH THE REAR OF THE VEHICLE. UNDER CLOSER EXAMINATION OF THE VEHICLE FOUND LOOSE/BROKEN COOLANT FITTINGS FROM BEHIND THE ALTERNATOR AND SOMEWHERE IN THE BACK OF THE ENGINE BAY. ENGINE WILL HAVE TO BE REMOVED TO PINPOINT THE SOURCE OF ADDITIONAL LEAKS. *TR

NHTSA ID

10509443

Incident

Feb 20, 2013

Mileage

40,000 mi

COOLANT LINE BECAME SEPARATED AND DUMPED COOLANT ALL OVER THE HIGHWAY CAUSING VERY SLICK ROAD CONDITIONS. THIS WAS ON A LONG HIGHWAY ROAD TRIP WITH THE ENGINE VERY WARMED UP AND WORKING. FAILING COOLANT LINES THAT DUMP ARE VERY DANGEROUS TO THOSE BEHIND THE VEHICLE, ESPECIALLY AT HIGHWAY SPEEDS. *TR

NHTSA ID

10509344

Incident

Apr 12, 2013

Mileage

58,000 mi

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