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Attention 2010/2011 Turbo and S Owners – Camshaft Controller Failure (US Safety Recall)

too_good

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All - I have just joined PCGB to highlight to fellow owners that defective bolts/screws used in the camshaft assembly of early mk2 (958) Cayenne 4.8 V8s built between 2010 and September 2011 can potentially lead to immediate engine, brake hydraulics and/or power steering failure. Porsche has issued recalls for these models in other countries accordingly over the last few years (details below). The aluminium bolts used in the two camshaft controllers are increasingly well documented as not fit for purpose and prone to shearing off in to, and stalling, the engine - potentially causing a crash.

I only bought my FPSH 60 plate CTT with 51k miles 2 months ago (having previously owned cars including 2 x BMW M3s, a Mercedes SL500 and their ML350 SUV) - my family and I love the car and I'm proud to own it, but feel disappointed that such a material design fault has gone unaddressed by a brand I have associated with ‘high quality’ - and indeed integrity. I have verified using a dental mirror that the faulty aluminium screws are, unsurprisingly, present. The tell-tale sign is whether there is a 'pin' in the centre of the bolts/screws used to secure the camshaft controller (if there is no centre pin, the bolts should be the replacement steel variant). I can post more on this if there is interest, but otherwise the forum posted below exhaustively covers this topic and covers technical aspects which are beyond me (my posts are at the end of the thread, including a picture of the offending bolt).

This is a fault known to Porsche, with affected models in the US subject to both a Workshop Campaign around 2013 (known as WC22) and a ‘live’ US/Canada-wide recall campaign (coded AH08) – per a 'Safety Recall Report' filed by Porsche North America with the US's National Highway Traffic Safety Administration (the equivalent of the UK's Driving and Vehicle Standards Agency) in May/June. The report filed by Porsche NA states: "On May 31, 2017, the product safety committee of Porsche AG came to the conclusion that...a safety related defect could not be excluded. It was therefore decided to conduct a voluntary recall of all potentially affected vehicles in the U.S. and Canada." This amounts to 17,986 Cayennes and Panameras (various Panamera models used the same faulty camshaft adjusters over a slightly longer period).

Tellingly, the NHTSA acknowledgment of the safety recall issued by Porsche asks them to "explain why this recall was filed in June 2017 when recalls for the same failure were initiated in April 2013 for substantially similar vehicles in Japan and during January 2015 for vehicles in China and Korea."

Whilst I can find no reports of this issue in the UK on the owner forums I have looked at, the body of US owners is much larger (and more vocal?!). Given the recall in various other countries and the fact that I have verified the same bolts are used in my UK car, it is reasonable to assert that our cars would also be affected sooner or later. There are reports of out-of-warranty owners having to pay $35k for a new engine or taking the hit on a preventative repair (costing c.$2,600) and I do not want to leave this issue unaddressed. I have checked the Workshop Campaign/recall history of the car and there is nothing relevant to speak of.

Regrettably, Porsche have seemingly elected to take no action in the UK (or other countries around the world) where the same faulty vehicles have been sold. Indeed, I have just called Porsche GB's Customer Assistance line to highlight the above and request that my car is repaired - the message was that they "cannot authorise a repair unless a GB recall has been issued." Naturally I am not happy with this response and do not accept it - as I told Porsche, I shall therefore refer this serious safety defect to the DVSA for their attention next week, along with the supporting documentation (WC22, AHO8 and the NHTSA letter). I’ll wait a few days as I am interested to hear from other concerned owners in the first instance.

FYI, I originally learnt of this fault via the active 6SpeedOnline community in the US (which has already helped me identify/solve an issue with lumpy acceleration attributed to dirty Transfer Case oil - another story, but the other component as far as I know which routinely can cause very expensive issues with 958 Cayennes – any model or year I believe). There are 39 pages of posts on the camshaft issue via the below link, with a similar story on another US Porsche owner forum (www.rennlist.com). It is quite possible that the coordinated efforts of those on the forums to raise the issue led to Porsche initiating the current recall (numerous owners filed reports with the NHTSA so it was likely only a matter of time before they investigated - point being, I would very much welcome it if you would reply to this thread if you also own one of these cars and share my concerns. Some coordinated action of our own is in order as it stands.

https://www.6speedonline.com/forums/cayenne-958/319690-snapped-camshaft-adjuster-bolt-engine-brake-hydraulics-failure.html
[FONT=credit suisse type light"] [FONT=verdana,geneva"]
[@Porsche GB – given your affiliation with PCGB, you may well read this! If so, I urge you please to do the right thing and proactively resolve this matter in short order.]
 
I have a Cayenne Turbo, model year 2011 delivered in July 2010 .. is this in the same category ?
 
I expect so Condor - AFAIK, the impacted vehicles are 100% of 958 Cayennes built between 28 April 2010 and 13 Sept 2011 based on the Porsche report.

If in doubt, perform the dental mirror check - take the oil cap off and put the mirror just over the other side of the chain, looking for a pin in the bolts.
 
Thanks for the update .. I'm not that technical, but will attempt your suggestion. If I see 'a pin the bolts' what are you suggesting ?
 
I'm not particularly technical either. Attaching pictures of the offending aluminum bolt on my car observed with the dental mirror (notice the pin in the middle of the top of the screw), as well as what the improved design of bolt looks like (steel ones with no central pin - these are also magnetic, whereas the faulty screws are not FYI).

If the pictures do not upload successfully, take a look towards the bottom of the page here:
https://www.6speedonline.com/forums/cayenne-958/319690-snapped-camshaft-adjuster-bolt-engine-brake-hydraulics-failure-38.html

I suggest we impacted owners report this 'serious safety defect' to the DVSA - if several of us collectively raise the issue to them, I am hoping that this prompts them to investigate sooner rather than later and compel a recall. Excerpt of DVSA website below (clearly the authorities in other countries have deemed this a 'serious safety defect' which Porsche must rectify, with Porsche's own safety committee also coming to the same conclusion). I have raised the matter to Porsche GB to no avail so it is reasonable to now refer it to the DVSA. Safety aside, should the issue arise and the owner has no warranty, the potential repair cost is enormous. Regardless of a warranty covering the repair cost, there is the inconvenience of potentially being stranded in the first instance and the lead time to repair possibly running to weeks/months (e.g., if a replacement engine was required) - I want a car I can trust and rely on with my young family.

---------------------

https://www.gov.uk/vehicle-recalls-and-faults/report-a-serious-safety-defect
[h1]Report a serious safety defect [/h1]If you find a serious defect that affects the safety of your vehicle, one of its parts, or an accessory, report it to the manufacturer immediately.
Tell the Driver and Vehicle Standards Agency (DVSA) if you’re not happy with how the manufacturer is dealing with your report.

DVSA will:
  • investigate the issue with the manufacturer
  • tell you what action is being taken
The vehicle, part or accessory can be recalled if it’s found to be a serious safety issue.
[h3]What counts as a serious safety defect[/h3]A serious safety defect is something:
  • about the way the vehicle is designed or made that’s likely to cause injury or death
  • that happens suddenly and without warning
Only report a ‘serious safety defect’.
 
Thank you for the link .. I have had my KN from new, and have taken Porsche extended warranty every year. It is in place until beginning of November 2019.

I will check with a dental mirror .. and report back.
 
Hi

I've got 957 is on a 58 plate so previous model and built before the 28 April 2010 date mentioned, but I thought the same engine. So presumably there was a change in spec from the 957 4.8 to the 958 version.
Is there a link to the Porsche recall with VIN number so one can be certain if affected without getting hold of a dental mirror?
 
Neil - thought was a brand new engine for 958 (and new Panamera), but agree they appear the same on paper. The Porsche recalls have not covered the UK for this fault so no insight via a VIN checker I assume, but the Safety Recall Report related to current US recall is at below link (NB: ranges are for US cars only I believe though):

https://porsche.oemdtc.com/Recall/AH08/RCLRPT-17V368-6172.PDF

Your local OPC or indy will no doubt know if it's same engine (but perhaps not about this camshaft fault).

Cheers



 
... so here is a photo, taken as you suggest ... can I please ask what it tells you ?

[attachment=Cayenne.jpg]






 
An excellent picture of the bolt condor, thank you for posting. It tells me that you have the offending aluminium bolts I am afraid (unsurprising, given your model year of CTT). As you can see, the 'pin' is clearly visible in the centre of the screw - the newer/steel design simply has an indent/depression in the middle like a normal screw head. I am unable to attach pictures for some reason, but the following post has clear pictures of both the faulty and replacement design (towards the bottom of the post):

https://www.6speedonline.com/forums/cayenne-958/319690-snapped-camshaft-adjuster-bolt-engine-brake-hydraulics-failure-30.html

FYI, I have reached out for quotes on a 'preventative' repair from various London workshops (an OPC and various independent specialists), with prices expected this week - note that one independent has advised that they have carried out several such repairs (mainly for Panamera owners; same engine), as well as full engine replacements as a result of the bolts shearing off in to, and destroying, the engine. Watch this space for more details.

[I thought more people may have chipped in to this thread, but I suppose there aren't too many 'S' and Turbo owners in the UK in relative terms, let alone for these model years and also active members of PCGB. I shall post this on the Panamera forum too to spread the word.]
 
I've been in touch with my OPC .. they're asking me "[FONT=porsche next"] I need to understand why you believe this part is at fault on your vehicle."[FONT=verdana,geneva"]
[FONT=porsche next"]I've downloaded the four photos which you've kindly shown me on the link, but the 'up hill' part is getting evidence that there is a problem .. any suggestions please ?[FONT=verdana,geneva"]

Cheers
 
Go here and print off the NHTSA (US road safety body) letter and dossier of affected vehicles.

https://porsche.oemdtc.com/129/camshaft-controllers-may-loosen-and-fail-2010-2012-porsche-panamera-cayenne

There is also a Porsche Workshop Campaign (WC22) with exact instructions online somewhere else (I do not have link to hand) - related to a voluntary recall in US for only certain VIN # (despite it affecting ALL early 958 model cars).

As you know, there is an in-flight safety recall in the US initiated by Porsche NA (on back of recalls in Japan and China in recent years), with Porsche GB or AG not following suit despite this affecting all cars built in the above period globally.

Interested to hear how it goes.

Please let me know what you get quoted. I have heard back from my nearest OPC and quote is an approx 50% too high £2800 inc. VAT (no questions asked re: "why the repair" by the way). I asked for parts vs labour split upfront, but they did not provide it. Expecting/hoping Indy price to be much closer to £2k when I hear back this week as parts prices pretty fixed and labour should be no more than 6-8 hours at approx £90 per hour inc VAT.
 
The OPC confirmed that the photo I provided was indicative of the bolt in question .. my car is covered by a Porsche extended warranty until November 2019. The OPC said that since my car was not on a recall list, nor was I having any problems, that since my car was covered by warranty, no action was needed.

So I've not received a quote to get the work done. Typing to you this morning, perhaps I should at least ask Porsche what the cost would be, even though my car is covered for most eventualities.
 
Having read the NTSB letter, I'm 'on the case' .. I'm demanding my repairs under warranty .. I'm not waiting until the parts fail.

 
Look forward to your next update condor. As you will have seen in the letter, Porsche AG's own 'product safety committee' acknowledges the risk and potential for catastrophic sudden failure owing to this defect - it is hardly acceptable for UK owners to have to 'hope for the best' that it doesn't happen.

Tellingly, the NHTSA acknowledgment of the safety recall issued by Porsche asks them to "explain why this recall was filed in June 2017 when recalls for the same failure were initiated in April 2013 for substantially similar vehicles in Japan and during January 2015 for vehicles in China and Korea."

I don't think Porsche GB reasonably have a leg to stand on and their handling of this issue is disappointing and worrying to say the least. I'm going to write to Porsche GB HQ today accordingly. Let's see how we get on. The next step would be us reporting this serious safety defect to the Driver and Vehicle Standards Agency (DVSA). Not the 'PR' Porsche would welcome I am sure, but they appear to be opting to dismiss that there is a problem/risk wrt UK cars.
 
Here's the response from the OPC ..

[FONT=porsche next"]"I have now put together an estimate to replace the camshaft actuators on your Cayenne as requested.[FONT=verdana,geneva"]
[FONT=porsche next"]The cost to replace the bolts in these units, should all the bolts be tight/present would come to - £1486.32 Inc VAT[FONT=verdana,geneva"]
[FONT=porsche next"]Should there be any bolts that have loosened or are missing then the actuators will require replacement - The costs for this would come out at £2361.94 Inc VAT[FONT=verdana,geneva"]
[FONT=porsche next"]As mentioned, if you have experienced no issues with your vehicle there is no need to carry out this repair. Any issue you may face of this nature will of course be covered under your extended warranty."[FONT=verdana,geneva"]

[FONT=porsche next"]Question for you please .. 'what symptoms could I have experienced ?'[FONT=verdana,geneva"]
 
A very interesting response. My understanding based on reading 39 pages of posts in the US owner forum (link below) is that it is not possible to simply replace these particular aluminium bolts (if only it were that easy) - indeed, the tell-tale pin in the bolts is a 'security' feature essentially as I understand it - their use indicates to any technician working on the car that these are one-time use; more importantly, they are not designed to be unscrewed and replaced like typical bolts. The new design used from late 2011 is all-steel, with zero reported issues.

Moreover, the prior US workshop campaign, recalls in China/Japan/Korea and the current US/Canada recall all involve complete replacement of the Variocam camshaft controller assemblies.

The fact that the OPC is entertaining that some bolts may be loose or even missing (!) is alarming in itself and arguably corroborates the material design defect here (partly attributed to the bolts being too short as I understand it, working themselves loose over time - they would/should stay firmly in place for the lifetime of the car if fit for purpose!). Additionally, on the basis that the OPC claims to simply to be able to replace the bolts, this could point to a lack of technical understanding here.

There are very unlikely to be any symptoms as such (maybe some rough idling at a stretch)...the ongoing risk here is that a bolt fails suddenly with no warning rendering the camshaft controller inoperable to an unpredictable degree; your dashboard lights up like a Christmas tree and you wrestle the car off the road (without crashing and no engine damage if lucky)...or a bolt drops in to the engine and you stall on the spot (hopefully not in the outside lane of the motorway, etc., with a new engine required worst case). A quote from the very first post on the US https://www.6speedonline.com/forums/cayenne-958/319690-snapped-camshaft-adjuster-bolt-engine-brake-hydraulics-failure.html forum (4 years ago!):

"My family was driving our 2011 Cayenne S on the freeway the other day and they saw the following lights: PSM failure, Check Engine, Start/Stop deactivated, ABS. They were on the freeway and they pulled off and soon after the engine completely died and would not turn on. The dealer called
today to say the camshaft adjuster bolt had snapped off and as a result, the hydraulic brake system also failed."

You can glean a lot from only reading page 1 of the above forum - suggest you do, if not already condor.

Take it you gave the OPC your PCGB number such that you got a parts discount quoted? Intriguing how much 'resistance' you continue to get here from them - wonder if there is a global Porsche shortage of parts as they are fixing 18k cars in North America right now so keen to avoid having to tell you it'll take a while to fix?!

At the very least, I would get the bolts checked out by your OPC (and demand this is done FOC) - if there is any sign of loose or missing bolts, your hand is strengthened further. Even if not though, the risk remains of sudden failure at any time in principle. FYI, a decent Indy will typically offer free inspections (put car on ramp and take a look, etc.) so also an option.

In other news, I wrote to Porsche GB on Wednesday night and they responded this morning (a swift reply to be fair) - same message as on the phone: "Porsche GB will not authorise any replacement of parts unless a campaign or recall, directed by Porsche AG, for your vehicle is released. We do appreciate the time taken to write to us, detailing the campaigns carried out in other markets. We can highlight this to our Warranty Department for comment, if they can provide further clarification on this we will write to you by Friday 3 November."
This is unacceptable of course, with the global recall process seemingly a lottery whilst material safety risks acknowledged by Porsche AG persist - they have recalled c.35k+ cars globally, but see fit to take zero action in the UK. I have sent PAG's response on to Porsche AG inviting them to do the right thing.
 
Update: I have had the camshaft controllers replaced on my CTT at a specialist in North London familiar with the work (crucial for me given the complexity involved replacing such an integral engine component - they charged 8 hours labour, but it's a 2 or 3 day job in practice to include thorough road testing, checking engine timing, etc.). The price was lower than the local OPC and of course they used only official Porsche parts - the replacement controllers are the latest/uprated design so I have peace of mind. The workshop reiterated that they have seen several Panameras (and one CTT) come in with sheared bolts, with engine replacements required for some unlucky owners. The lead mechanic said that he would have done the same work if he owned an early Cayenne V8 given the defect/ongoing risk.

Whilst Porsche GB to be fair did look in to my compliant further after initial resistance, by contrast, their response was the repeated message that my car is not one of the affected VINs so no action is required. The response also stated that even if the bolts in my car are the same as those in the vehicles included in the recall/workshop campaign, this does not mean they are defective and need to be changed! Per previous posts, the whole point here is that all these Cayennes are made in the same Slovakia factory and whilst 35k cars have been recalled to address safety risks across other countries, no action has been taken in the UK despite the cars being identical for all intents and purposes.

Anyway, I reported the issue to the DVSA last month and they are investigating, in concert with Porsche themselves. I reasonably expect reimbursement for the preventative repair I have carried out. Note that owners on the US forums took coordinated action - that is to say, numerous owners reported the issue and safety risk to the US authorities (NHTSA) - clearly this will have raised its profile. A chorus from owners on this forum would no doubt help the cause, but I expect I am the only owner in the UK to have referred this defect to the DVSA. Please do get in touch if you would like to report this to the DVSA - it is very straightforward and in all our interests.
 
As you know, I have taken the issue up with my OPC, and they refer to my car as 'not being in the batch requiring recall'.

Why do you think you reasonably expect recompense from Porsche UK, when they refuse to admit there is a problem with UK supplied vehicles ?


 

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