Coolant Leakage - Boxster S

stevebeestin · Nov 2, 2015

I have a Boxster S, 3.2 manual, 2004 - the car, purchased in June, is used daily for work - after a short trip yesterday ( 4 mile round trip ) - the coolant light on the temperature gauge began to flash, as we were only 400 or so metres from home, I didn't worry & just thought I'll check the coolant levels when the engine had cooled.
Unfortunately, having parked the car - I noticed coolant "pouring" from under the front passenger side wheel arch, as this was Sunday lunchtime, I haven't had chance to speak to anyone as yet....Does anyone have an idea as to what the issue is ??
Many thanks,
Steve B.

Hoopster · Nov 2, 2015

Hi Steve,
I've just had a similar issue, although I was lucky enough to catch a small leak during an MOT inspection, before it got too serious.
Sounds like the coolant cross over pipes. there are coolant pipes across the front of the car, and the joints are rather exposed in the wheel arch area. Hence they corrode over time (c. 10 years) and need replacing. You'll see the curved connector pipes in each front wheel arch.
Adam

Chappelle · Nov 2, 2015

On the 987 there are two coolant pipes that cross the front of the car. There are two connections each side where you describe the leak is coming from. At a recent inspection of my car at the OPC the connections were pointed out as a weak point. I did some work on my sons 986 and I think the setup is similar. hope this helps

Motorhead · Nov 2, 2015

Steve,

Have a look at this link:

https://www.porscheclubgb.com/forum/tm.aspx?m=817094&mpage=2

Jeff

stevebeestin · Nov 2, 2015

Many thanks for your respective feedback - there seems to be a consensus of opinion as to the fault !! I'll check to see if I can spot the problem parts.
It is a little concerning, the dealer supplied a full 12 month MOT ( no advisories ) in late June...
At the time of purchase, I took out a third party warranty for 12 months - does anyone know if this issue is likely to be covered ?? Unfortunately, I'm away from home and do not have access to the paperwork until later this week....
Many thanks,
Steve B.

Motorhead · Nov 2, 2015

Steve,

Third party warranties are notoriously flaky. Best to identify the source of the problem and give the insurer a call to confirm that you're covered for the total expense; parts and labour. From your description it sounds as though the leak is particularly bad, so you may need to get the car trailered to a convenient repairer by your breakdown insurer.

Good luck!

Jeff

stevebeestin · Nov 4, 2015

Just an update...had the car recovered to my independent garage Monday evening - problem was connected with the crossover pipes, but also the nearside front radiator had failed (corrosion) hence the heavy/rapid loss of coolant from below the wheel arch !! I'm informed that this not covered by the third party warranty, so I'll just have to bite the bullet...
Many thanks to all who provided feedback !!
Steve

CLIFFWILKINS · Nov 4, 2015

Make sure you keep the front air vents clear of leaves and debris which can accumulate and cause corrosion.
Cliff

Motorhead · Nov 4, 2015

Glad you've got it sorted Steve - a pity it's not covered by your warranty, but typical I'm afraid.

If you're interested in avoiding future radiator damage, check out this link:

https://www.porscheclubgb.com/forum/tm.aspx?m=893048

Jeff

spikey1 · Nov 5, 2015

check front 2 radiators & pipes clips drain plug leaks.

stevebeestin · Nov 12, 2015

Coolant leakage - Chapter 2 !!
Having had the radiator & pipes replaced (£700 + 5 days in the garage !!) - I collected the car & managed to drive 26 miles, before a kindly motorcyclist pulled up alongside me at some traffic lights & advised that I had "liquid" dribbling from beneath the rear of the car !! Once again, I parked up the car & had it recovered to the garage on Tuesday of this week. I'm now informed that the coolant was dripping from the overflow tank, but they can find no reason for this, i.e. all fans are working, no leaks, system has been properly bled, etc.
Anyone shed any light on this ?
Many thanks.....

Motorhead · Nov 12, 2015

Just a thought Steve but did your garage replace the coolant filler cap while they were at it?

Also, bleeding the system fully can be a bit tricky but I presume that your garage is familiar with the recommended procedure for a Porsche.

Maybe the system was just over-filled?

Perhaps you should just run the car for a few days and keep an eye on the coolant level after each journey as well as the coolant temperature during the journey.

Jeff

Nick7602 · Jun 8, 2020

Hi Guys

had similar situation, just purchased the Cayman sat in a Costa Coffee parking area enjoying the fact we were now the owners of a beautiful Porsche, when my son came back after collecting some coffees and said there is smoke coming from the side air intake drivers side, investigation revealed the dealer had filled the coolant way to high, kept an eye on it since February this year when we purchased the car and no leaks thankfully

Kind Regards

Nick

adrian55 · Jun 8, 2020

Hi Steve , I suggest you replace coolant cap - a known problem - have had 2 pack up on two of my Boxsters 2005 and 981 2013 !

SarlechS · Jun 15, 2020

likely to be the cap if the cross over kit has been replaced, did you purchase the full crossover kit and do you know how many pipes were replaced? they should all have been done at the same time.

Nick7602 · Jun 15, 2020

I think as a belt and braces job, I will replace coolant pipes with the kit

Motorhead · Jun 15, 2020

Not a bad idea Nick ... but the problem is where do you stop? With the engine at the rear and the radiators at the front there's a lot of pipework and plenty of junctions with those suspect connectors, although the front cross-pipe connections are the most vulnerable. Regrettably the design has been carried-over to the later cars so there'll be plenty of future work for the Dealers and Independents.

Jeff

Nick7602 · Jun 15, 2020

Morning jeff

Yes indeed, when and where do we stop, checking the history of the vehicle the coolant cross over pipes were changed in 2018, im now told mine have corroded again and exhibit signs of coolant leak, im just wondering if the signs of a leak are from having the pipes changed in 2018, or do these pipes need to be replaced every couple of years?

Kind Regards

Nick

Motorhead · Jun 15, 2020

Nick,

Unless the job was bodged the connectors shouldn't have corroded in a couple of years, at any rate sufficient to cause leakage. I don't have any specific evidence, but depending upon mileage it seems to occur mainly on the 987 Gen1 or maybe early Gen2 cars, although I'm sure that some 981 owners could also be experiencing the problem.

Do you have any bills to indicate where the job was done and what was changed? If so I'd be having a conversation with the repairers.

Jeff

911hillclimber · Jun 15, 2020

I'm relatively sure Porsche would design the parts to last the warrantee period, so all should be good for 2 years and more.
My 2009/61K miles 987.2 cross pipes/connectors are corroded but still have their full shape and are not wet BUT I am still loosing some fluid. All pipes under the car are OK, checked by a reputable indie a few months ago.
I replaced both caps with real OPC ones and have noticed some white residue at the outside surfaces of the boot mounted cap under the cover, looking like dried fluid. Not a lot but some.

I feel the O ring in the cap is not compressed enough when the cap is secured tight (and I mean well hand tight) and the logo on the cap is horizontal, ie fully home.
Might try to fit a plumper O ring soon. I now have the fluid a few mm below the MAX yellow marker.

My faith in Porsche design is poor....