2004 Porsche 911 GT3: engine overheating

Filed Jun 20, 2013 · Engine · 14,600 miles · WA

This is in response to my awareness of the federal safety agency pe13-009. I am the third owner of a 2004 porsche gt3 that I use primarily for track driving days and occasionally for street use. When I purchased the car in 2010, I was aware of many reports from owners of similar cars that had experienced sudden coolant loss from any of eight glued-in tube-like aluminum fittings to which coolant hoses are attached. The reports described the catastrophic effects of coolant loss, primarily on the track, that in some cases resulted in loss of control to the affected car and/or loss of control to cars following that car. A number of crashes were reported. These reports are contained in various online forums, including rennlist.com. Because I was concerned about the possibility of this failure occurring to my car, I prophylactically had my engine removed and all eight coolant pipes welded into the aluminum manifolds that they had originally been glued into. I did this at a cost of $2500. I think it would be prudent for porsche cars north america to recognize the issue created by this poor design and correct it by recalling cars that have not been repaired, and reimbursing owners, like me, who took it upon themselves to correct the problem before there were any consequences. It is interesting to note that various similar-engined factory race cars made by porsche during that era, including the 2001 gt3 rs that I own, used a completely different (and more robust) threaded means of attaching these coolant fittings to the coolant manifold.

Filed Jun 14, 2013 · Engine · 20,000 miles · TX

I purchased my 2004 porsche gt3 in may of 2009. It had just under 20,000 miles on it. In august, 2010, I was driving on track at texas motor speedway and one of the coolant fittings came loose from the engine. The epoxy that holds the press-fit coupler to one of the heat exchangers had lost its ability to retain the fitting and came disconnected. All of the engine coolant was lost in a single instance. [catastrophic coolant loss]. I had that fitting replaced by the porsche dealer in dallas under aftermarket warranty. I can provide info regarding the on this at your request, and I have some pictures of the offending part. I had a second (and separate) fitting fail in january 2011 at 35,000 while driving on track at motorsport ranch houston. They same symptoms were found - the press-fit coupling had come loose resulting in complete coolant loss. This was also repaired with a factory replacement part under aftermarket warranty at the porsche dealer in houston. I believe there are 8 known press-fit couplers on the gt1 engine block in the 996 and 997 model gt and turbo cars. Each of these is known to fail based on the press-fit coupler and poor design (use of epoxy on a high pressure component). I understand that this is a known problem on porsche gt/turbo cars and has been discussed on the internet (e.g. Rennlist) for many years. 25% of mine have failed, and almost every other gt driver I know has had at least one fail.

Filed May 28, 2013 · Engine · 51,000 miles · WA

Experienced sudden coolant loss while driving on public roadway. A bonded-in aluminum tube (spigot) on the coolant distribution manifold popped off, resulting in a massive, instant coolant loss. The coolant dumped all over the rear tire, causing the vehicle to go in to an uncontrollable skid, rendering the vehicle inoperable. Luckily myself, my passenger, and no one else was injured. My vehicle is currently at a porsche independent shop in seattle, wa where the engine is being removed from the vehicle to address this failed fitting as well as address all coolant line fittings to prevent future glue failures. The shop is welding all coolant fittings as it seems the factory glue is not sufficient at holding the aluminum tubes together. Total out of pocket cost to me is estimated to be more than $4500 for parts and labor. The following article written by a porsche tuner does a very good job of explaining the problem in detail: http://sharkwerks.com/porsche/technical-articles/327-the-gt1-coolant-pipe-prevention-fix-on-gt1-block-gt3-gt2-turbo-cars.html additional information ascertained from research and discussion with reputable porsche independent shops, race teams, race shops: in these engines, coolant/anti-freeze circulates through aluminum castings and rubber hoses. Hoses are clamped onto aluminum sleeves that are inserted into the bores of the castings and held in with adhesive. Problem: adhesive eventually fails, which allows the sleeves to "blow" out of the engine, resulting in a sudden loss and spillage of slippery coolant/anti-freeze onto the vehicle rear tires and road surface. This causes an immediate and dangerous loss of traction to any vehicle driving through the spill, including the one spilling the fluid.

Filed Apr 16, 2013 · Engine · 12,500 miles · NY

Engine has press fit (and glued) couplings for coolant lines. When coupling fails, there is rapid coolant loss which is a toxic hazard as well as potentially dangerous to traffic.

Filed Jan 30, 2011 · Engine · 35,000 miles · TX

Porsche gt1 engine press fit coupling for coolant lines. When coupling fails, there is rapid coolant loss which is a toxic hazard as well as potentially dangerous to traffic. Also, without coolant the engine is in jeopardy of overheating.