2004 Porsche Cayenne S Ignition Coil Defects
#1
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This is a follow up to my posting here: https://rennlist.com/forums/porsche-...en-cold-2.html
I thought I post my findings here in appreciation to all the helpful comments - especially from mudman2!
See their cracked casing below ...
Cylinder 7: https://picasaweb.google.com/lh/phot...eat=directlink
Cylinder 6:
https://picasaweb.google.com/lh/phot...eat=directlink
Cylinder 5:
https://picasaweb.google.com/lh/phot...eat=directlink
The casing of these ignition coils are made of PET fiber glass re-enforced plastics. Something like these from DuPont: http://plastics.dupont.com/plastics/...ite/RYNPPe.pdf
Whoever Porsche uses for supplier for these ignition coils should be taken off the qualified supplier list as this is obviously poor quality in manufacturing.
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
:g rr:
Whatever happened to the ISO9000/QS9000 standard!?!?!?!? My Cayenne S only has 45,000km or so on the odometer so clearly THIS IS CLEARLY A MANUFACTURING DEFECT WHERE THE PLASTICS FAILED UNDER STRESS.
I thought I post my findings here in appreciation to all the helpful comments - especially from mudman2!
See their cracked casing below ...
Cylinder 7: https://picasaweb.google.com/lh/phot...eat=directlink
Cylinder 6:
https://picasaweb.google.com/lh/phot...eat=directlink
Cylinder 5:
https://picasaweb.google.com/lh/phot...eat=directlink
The casing of these ignition coils are made of PET fiber glass re-enforced plastics. Something like these from DuPont: http://plastics.dupont.com/plastics/...ite/RYNPPe.pdf
Whoever Porsche uses for supplier for these ignition coils should be taken off the qualified supplier list as this is obviously poor quality in manufacturing.
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
![grr](https://rennlist.com/forums/graemlins/cussing.gif)
Whatever happened to the ISO9000/QS9000 standard!?!?!?!? My Cayenne S only has 45,000km or so on the odometer so clearly THIS IS CLEARLY A MANUFACTURING DEFECT WHERE THE PLASTICS FAILED UNDER STRESS.
Last edited by rting; 03-31-2013 at 03:38 PM.
#2
Rocky Mountain High
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PCNA actuall issued a recall for defective coils. If your vehicle needed coil replacement and you met their criteria (correct range of VIN numbers, work done at a Porsche dealer, etc.) then they reimbursed you for replacement coils. I had this done for my 2004 CS.
#3
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Additionally, the way that the cracks appear along the length of the casing seems to suggest that it is poorly injection molded. That is, the cracks appeared to be parallel / matching the flow of molten plastics. In effect, whoever made these for Porsche knows NOTHING about injection molding of such a critical component of the engine.
#4
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I was not very impressed with the Vancouver dealer when I asked them a couple of questions (Even though I was the only customer in the place)
If Porsche does not cover the cost just buy 8 new in the U.S ($270) and have someone else change them. For $500 it is not worth the hassle of fighting with them.
Or if you want to sell that lemon my Dad is looking for a Cayenne
If Porsche does not cover the cost just buy 8 new in the U.S ($270) and have someone else change them. For $500 it is not worth the hassle of fighting with them.
Or if you want to sell that lemon my Dad is looking for a Cayenne
![Stick Out Tongue](https://rennlist.com/forums/images/smilies/tongue.gif)
#5
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I was not very impressed with the Vancouver dealer when I asked them a couple of questions (Even though I was the only customer in the place)
If Porsche does not cover the cost just buy 8 new in the U.S ($270) and have someone else change them. For $500 it is not worth the hassle of fighting with them.
Or if you want to sell that lemon my Dad is looking for a Cayenne![Stick Out Tongue](https://rennlist.com/forums/images/smilies/tongue.gif)
If Porsche does not cover the cost just buy 8 new in the U.S ($270) and have someone else change them. For $500 it is not worth the hassle of fighting with them.
Or if you want to sell that lemon my Dad is looking for a Cayenne
![Stick Out Tongue](https://rennlist.com/forums/images/smilies/tongue.gif)
I got off the phone today with PCNA and it seems that they are willing to reimburse the cost if done at an authorized dealer - on the phone so they claim. I guess whether or not I am actually going to receive reimbursement, I guess it is a risk I will have to assess ... and will post the findings here.
Rest assured that even within my small circle of friends, I am not the only one who has a Porsche. This will be a subject matter of discussions when the name Porsche comes up over beer or coffee.
BTW, MCL was quoting me the other day about $900 plus tax on replacing all ignition coils.
Your 928 looks way cool!
Cheers,
rting
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#8
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Just realized that the above pictures of the defective ignition coils cracked housing are gone and no longer available with Google's Picasa.
So I put it here:
https://app.box.com/s/311ww4hm1p9d9t83j501gzghn02taodd
https://app.box.com/s/99zsz2u7wlx0ajh6bh80fdwbkqbv6s5z
https://app.box.com/s/1k48iv4vvc6sbml076rm9gs5455jrift
The 3 pictures totals a little over 28MB if you want to download them.
Injection molded plastics cracking is usually indicative of a number poor manufacturing practices and/or design issues. That, however, is not a subject matter of this forum on Porsche.
So I put it here:
https://app.box.com/s/311ww4hm1p9d9t83j501gzghn02taodd
https://app.box.com/s/99zsz2u7wlx0ajh6bh80fdwbkqbv6s5z
https://app.box.com/s/1k48iv4vvc6sbml076rm9gs5455jrift
The 3 pictures totals a little over 28MB if you want to download them.
Injection molded plastics cracking is usually indicative of a number poor manufacturing practices and/or design issues. That, however, is not a subject matter of this forum on Porsche.
Last edited by rting; 10-08-2016 at 11:28 AM. Reason: new url link to each picture
#9
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I'm years late to this page, but would you happen to know what VIN numbers qualify for the recall? I've got 2004 Cayenne S As well.
#11
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Coil packs are a huge money maker for Porsche. They aren't going to change that! I have yet to come across a Porsche with over 70k miles who's coil packs haven't been replaced. Go visit some of the newer model Porsche forums and you will see coil packs are still a common replacement item just like control arms.