Low Coolant warning problem

I am a new 2007 Cayman owner and have a problem that I wonder if anybody else has experienced. The very evening that I picked up my car from the dealership, my low coolant warning light came on. The light was coming on when the car was first started and then would go off after about 3 to 5 minutes of driving. I needed to wait until the next morning to check the coolant level and it was indeed below the minimum level indicator. I immediately took the car back to the dealer service for correction. They performed a pressure check, it checked out normal and they replaced the small amount of coolant missing. They suggested that it might have had an air blockage in the system that didn't allow a full filling of coolant from the factory. Everything was fine until a couple of days ago and the coolant warning light came on again. Same symtoms, the coolant was below the minimum level and I have returned the car to the dealer service. They ran an overnight pressure check and again it was normal. There is no observable coolant leak on the car or the floor. They have been in contact with Porsche technical service and they are suggesting to make sure that there is no coolant in the oil and something other to do with AC. The car only has 700 miles on it at this point. Has this issue been discussed or complained about previously? Any input is appreciated. It is obviously very bad if the coolant has infiltrated the oil lubrication system. The coolant has to be going somewhere! Thank you from a new member. MisterHarleyDad

Welcome to the club!!!! I would still take your car back to the dealer, but you might want to check out the link below and the subsequent jump after this link to read up on some other members that have complained of a coolant leak. Although you have said there is no noticeable leak, the coolant has to be going somewhere. Of course there could be a fault in the sensor or as the service tech suggested, air in the system, but a trip to the dealer is in order. http://www.planet-9.com/cayman-chat/13878-coolant-leak.html Good luck and let us know how things turn out.

I had this. I think just bubbles in the system. After a few times it will reach the right level. Took me 3 times.

Thank you for the responses...the car is at the dealership and they should let me know more information tomorrow. They will be checking the oil. I sure hope it is air in the system. Thanks again...I'll let you know!

uh oh, big problem! Well, my worst fear has been confirmed. The coolant has gotten into the oil lubrications system somehow. The dealer is in contact with Porsche Germany and is getting specific instruction on how to deal with this issue. The service manager tells me that they need to determine where the problem is occurring. He said that they may need to take the cylinder heads off and inspect the casing of the cylinders. This doesn't sound good at all. This is a major repair for a car that only has 740 miles on it. As I mentioned, the original problem began on my drive home after purchasing the car. I'm not sure what will transpire. I feel as though I will always have a less than perfect car. I will know more tomorrow what they might have to do or intend to do. Ugh...disappointed doesn't begin to describe my feeling. Stay tuned. I sure wish somebody else out there had a similar complaint that was resolved satisfactorily.

Wow, that is a major defect! Check into your lemon laws just in case.

seems to me your gasket's busted, causing the coolant to leak into the oil or vice versa depending on pressure differences. Most probably both ways. Considering the age of the car, an engine swap might be in order.

I actually contacted a lemon law attorney (I am in California). Apparently Porsche is one of the most difficult manufacturers to claim against for a lemon law issue. He specifically told me that they won't take a Porsche case unless there are 4 visits for the same problem. I've resolved myself to the issue and I will pursue a replacement engine and if not a replacement engine, then I will pursue an extended warranty. Clearly this is a major defect and I hope that Porsche will step up to the plate. I'm not holding my breath. More news tomorrow, I hope. Thanks for your comments.

Good news! I just talked to the Porsche service at the dealer and they were unable to locate the source of the intermix of coolant and oil. They had taken the engine out of the car and looked at all the areas that Porsche technical in Germany had directed. Apparently because they are unable to locate the precise problem, they are going to replace my engine. This is the best possible outcome because I would have always worried about the integrity of my original engine. My faith in Porsche is restored and I think they did the right thing. I have no complaint at this point...I should be able to pick the car up on next Monday.

Who did your service?

Yes, there are engines in the warehhouse...it was to take a day to ship it to Carlsbad.

similar problem hmm... I just bought a 2007 Cayman on my birthday in 9/2007. I drove it home, and show it to my friend that night. We found out that the coolant is low! It's below the minimum mark. On the advice of my sales person, I added some coolant myself. A week later, I recheck it again in the morning before I head out to work. The coolant is below minimum line again! I am going to take it to the dealer tomorrow for a check up.

Taxol, yes let us know what your dealer service folks report. The coolant has to be going somewhere...unless there is air in the system. Did your low coolant warning light illuminate?

when i had my z4 ....it had the same problem...my coolant would always be low and even after topping it off, adding more...whatever the dearlership thought might have fixed the problem...it would always still be a problem....my dealership would run those test on my cars as well and always came back to tell me that they couldn't figure out what the heck was wrong with it.....until my car overheated and blew the engine on the freeway....they then changed my engine for me......i was in a loaner for a month.

coolant followup I went to dealer today. They believe the coolant cap is faulty and replaced it. There is another 2007 boxter S with the same problem. Got his coolant cap replaced as well. I will post a followup.

Excellent News! I picked up my Cayman yesterday afternoon. The engine replacement was completed. They showed me all of the information as well as the paperwork that they had with communication to Porsche Technical in Germany. They are going to be returning the original engine to Porsche in Germany for a complete disassembly to determine what the actual cause of the coolant and oil intermix. The service manager suspects the possibility of porosity which can happen during the casting process of the engine block...rare, but it does occur. I really can't say enough nice things about the dealer and service...Hoehn Porsche in Carlsbad, CA. They were sympathetic and kept me informed each step of the way. They furnished me with a loaner car for the duration and asked me if there was anything else they could do. I have restored faith in Porsche as they did the right and proper thing. The car itself shows no sign, whatsoever, of being worked on but I know it must have looked like an open heart surgery! I hope I'm the only one who experiences this problem, but at least it is documented for others if they have a persistent low coolant warning problem. I wish mine would have been related to a defective cap; although this doesn't make sense to me as the coolant would then be obvious in the little compartment spill over retainer device. Anyway, thank you for all the posts and we'll chat more along the way.

That's a great story. Just a note I also just checked my coolant level visually at the filler cap on a cold engine and I could not see the coolant it was below the "MIN" mark. I called the Porsche service rep and asked if I should add coolant. He said not unless the warning light comes on - even if I could not see the coolant. Have you all heard of this before?

I took my car to a friend mechanic on Sat. for an oil change - while doing the oil, he noticed a white crusted deposit in few places - he suspects it might be the water pump seal based to the stain pattern - just for people's info - the coolant when it dries becomes white. I will pass on one more tip I got from him - we were looking at the tires , and he showed me where the wear marks are in the grooves - to locate them from the outside, look for the small Michelin icons on the side walls.

If the coolant is completely cool, and the level is below the "low" mark, it would seem self evident that you should add some to top it off. Waiting for the light to come on is probably a bad idea. I've noticed a small drop in coolant since I got my Cayman 11 months ago (nothing serious). But, every now and again, I would smell coolant after parking my car. It seemed like the kind of smell that you get when coolant spills on to hot metal... I installed an IPD plenum this weekend, and while I was in there I saw this: I'm pretty sure this is what others have complained about. Honestly, I didn't do anything to fix it while I was in there, but I'll probably just replace that plastic clamp with a real metal one at some point.

I saw the same white stain marks when I opened the engine bay....Just cleaned it up with a wet towel, thinking - "Oh, probably the chaps in Finland forgot to clean it" ... Now after reading your remarks, am getting a bit worried.....Coolant has always been low...Topped it up with distilled H20 twice - and its still low....no coolant light as yet...should I worry abt the white crusted stains...? Does everyone have it, or is it that only some of us are blessed..?

A pic of the stains....

Uh Oh I just went out and check my coolant level for the first time (car is 6 weeks old) and discovered that it is below the MIN mark. I saw no fluid. And there was a white flaky debris on the inside of the cap. Any suggestions? I've called the dealer but no reply yet.

Could this be the answer I found this on Suncoast Porsche, Audi, & VW . Could this be the answer to faulty Coolant Caps? Suncoast Porsche, Audi, & VW: Coolant Cap

That coolant cap pictured is an update for the early 996 cars (and likely the 986 cars). I haven't looked closely at the coolant cap on the CS but I would be surprised if the above pictured cap supercedes the CS cap as this cap has been around since prior to the production of the Cayman (Instead it is likely the the part no. from the above pictured cap is the same as what is on the CS).

Same Problem After reading these posts, I went out today to check my coolant level. I've had my 2008 Cayman for 6 weeks now. Anyway it was below the MIN mark, and I so I saw no coolant at all. I called my salesman and service manager, and they both told not to worry and to add distilled water. I went and bought some and ended up adding 1-1/2 cups. Then I drove the car for 20 minutes, parked the Cayman and went golfing. When I got home, I immediately checked the coolant level. I started to twist off the cap and heard a gurgling sound, then a sudden gush of water flushing from under the car. I looked under the car and saw a puddle of fluid near the right rear tire. I wiped it up and it seemed to be odorless. Then I started the car and drove it, without any problems, for about 15 minutes. I have no idea what's going on. I presume it isn't serious.

As is probably pretty clear to you now, you want to make sure that you *never* open any sort of radiator cap if the coolant is likely to even be warm. You have to remember that the system is under pressure and normally operates at about 175 degrees F. Depressurizing it while its hot will result in a geyser / spray of super heated fluid hitting you in the face!

To be clear, on my car (the first image in this thread) from the pattern on residue, I think the occasional spray is coming from the hose that is clamped with the cheap white plastic clamp...

Emm...Hope all this liberal spray of coolant into the engine bay doesnt find its way into something somewhere that would make the whole thing go kaput... Now, only if someone designs a ?metal clamp and check tht the coolant is holding well - we could test the theory. For what it is worth, am taking the CS into the dealer in 2 weeks to see what they say abt the white crusts. By the way, Yancy - a very informative and claer write up on the plenum install.....Thank you.

Doc: thanks! I wouldn't worry too much about damage from the amount of spray you and I seem to have from the images above -- the engine is mostly open to the environment anyway (I had small twigs on _top_ of my clutch housing).... Please do report back here as to what your dealer says...

Yancy Yes, I lucked out on opening that coolant cap. I wish I had read your post before doing so, but fortunately, there was no harm done.