rting

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.

: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.

Dennis C

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.

rting

Dennis C, my dealer did not even looked it up on their records as to whether this TSB is done or not. I actually e-mailed them a TSB pdf and they say that the cost to just look it over and do their tests is $150 plus tax. Granted, they may take time to look it over but I believe it is not my responsibility to be proactive about it AFTER I contacted the dealer stating that I suspect the coils need replacement.

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.

jcb928

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

rting

Hi jcb928,

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

rting

Mailing out the invoice to PCNA today ... will report back what happened.

rting

Just a follow up - received a refund for the full amount for PCNA today!

rting

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.

Magnus944

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.

Mark7000

Simply enter your VIN into the NHTSA site:

https://www.nhtsa.gov/recalls

Dan87951

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.

Murphey Parker

Has anyone tried the cosmo coils?

https://www.cosmoracing.com/porsche-...3-2006-4.5L-V8