NHTSA Complaint #10552741 — 2004 PORSCHE CAYENNE TURBO

OWNER OPERATES A 2004 PORSCHE CAYENNE TURBO, 4.5L V8 ENGINE. THIS VEHICLE, WITH JUST OVER 61,000 MILES BEGAN TO OVERHEAT FOUR DAYS PRIOR TO THE INCIDENT (DETECTED BY FLUCTUATING TEMPERATURE GAUGE). THE ENGINE COOLANT WAS FOUND TO BE LOW IN THE SERVICE BOTTLE BY APPX. 2 QUARTS WHEN CHECKED AND WAS REFILLED. THE EVENING BEFORE THE INCIDENT OWNER'S SPOUSE REPORTED A LOW COOLANT ALARM MESSAGE HAD DISPLAYED ON THE INSTRUMENT PANEL, COOLANT WAS ABOUT 2 QUARTS LOW IN THE SERVICE BOTTLE AND WAS REFILLED. THE NEXT DAY THE VEHICLE WAS BEING RUN AT 1500 RPM (FAST IDLE) IN A PARKED POSITION IN THE OWNER'S DRIVEWAY FOR A TEST WHEN A FLOOD OF ENGINE COOLANT WAS OBSERVED COMING FROM THE UNDERSIDE OF THE VEHICLE. VEHICLE ENGINE WAS IMMEDIATELY SECURED TO AVOID DAMAGE. AT THIS POINT THE VEHICLE WOULD NOT BE CONSIDERED DRIVABLE AND WOULD NEED TO BE TOWED TO A SERVICE FACILITY. AN INVESTIGATIVE TEARDOWN REVEALED A RUPTURED PLASTIC COOLING PIPE INSIDE THE VALLEY OF THE ENGINE, THIS FAILURE REQUIRED REMOVAL OF THE INTAKE MANIFOLD TO DIAGNOSE AND IS NOT A ROADSIDE-REPAIRABLE EVENT. THE EVENT CAUSED LOSS OF MORE THEN 50% OF TOTAL COOLANT VOLUME AS ONLY APPX. 1 GALLON WAS RECOVERED FROM THE VEHICLE PRIOR TO TEARDOWN. A PRESCRIBED REPAIR KIT FOR THIS FAILURE (REPLACEMENT COOLING PIPES KIT) WAS OBTAINED FROM SONNEN PORSCHE, SAN FRANCISCO CA AND INSTALLED BY VEHICLE OWNER. AFTER FILLING OF COOLANT AND TEST DRIVING, NO FURTHER PROBLEM WAS NOTED. *TR