Coolant: Service and Repair
Draining and filling in coolantTools
Preliminary work
1. Removing rear underside panel.
Cayman only:
2. Remove engine cover.
Draining coolant
Note: In order to facilitate assembly of coolant pipes and hoses smear with Kl�ber Syntheso Glep or alternatively Kl�berplus S06-100 assembly gel (available from the Porsche Parts catalogue)
Note:
^ Check Henn coupling O-rings and replace if necessary.
^ Clean push-in connector and coolant hoses before assembly.
WARNING: Danger of scalding from hot pressurised coolant.
^ Only work on the coolant system when the engine is "cool".
^ Wear protective gloves and goggles.
1. Open cap on expansion tank -1- and remove. Set steel chamber for bleeder valve to vertical -2-.
WARNING: Danger of scalding from hot pressurised coolant.
^ Only work on the coolant system when the engine is "cool".
^ Wear protective gloves and goggles.
WARNING: Coolant is corrosive and hazardous to health.
^ Skin and eye irritation
^ Wear protective gloves and goggles.
^ If you come into contact with coolant, wash off immediately with plenty of warm water.
2. Undo internal hexagon socket drain screw from coolant inlet pipe. Open spring clamp on hose at inlet side of the water pump, remove the hose and unscrew the drain plug. Collect coolant in a clean container. Next reassemble the hose and screw the drain plug back with a new sealing ring. Tightening Torque: 7.5 Ft. lb. + Ft. lb.
WARNING: Danger of scalding from hot pressurised coolant.
^ Only work on the coolant system when the engine is "cool".
^ Wear protective gloves and goggles.
WARNING: Coolant is corrosive and hazardous to health.
^ Skin and eye irritation
^ Wear protective gloves and goggles.
^ If you come into contact with coolant, wash off immediately with plenty of warm water.
3. Drain any remaining coolant by removing inlet hose to water pump -1-. Collect coolant in a clean container. Attach inlet hose again.
4. Remove inlet and outlet hoses from radiators Do this by pulling off the spring clips for the two Henn couplings -1- and pulling the hoses away from the coolant pipes -2-. Collect coolant in a clean container. Now reattach the clips in the right position in the couplings and insert the hoses The connection should audibly snap into place. Check correct positioning once again by pulling on the hoses.
5. Remove heating hoses on underside of car. Secure the pipes with hose clips and then open the spring clips Remove both hoses and slowly open hose clips. Allow coolant to drain into a clean container. Clean hoses, stick them back and attach the clips. Check that the hoses are firmly in place.
Filling coolant (includes bleeding)
Note: The process of filling and bleeding the cooling system continues to be performed using the special tool Radiator filling device 9696.
Note:
^ If a vacuum does not build up, there is a leaking valve in the coolant circuit.
^ Deformation of the rubber hoses of the cooling system is normal.
^ When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has been built up.
^ After both shutoff valves on the vacuum pressure gauge have been closed and the compressed air supply has been disconnected, the vacuum must not drop. If the vacuum drops within approx. 30 seconds, there is a leak in the coolant circuit.
1. Screw cap adapter for coolant expansion tank (K22) onto the tank and attach flexible extension (Fz 100) to the cap.
2. Connect vacuum pressure gauge of bleeder tool to the flexible extension. When doing so, ensure that both shutoff valves are closed (positioned at 90° to flow direction).
3. Connect the Venturi nozzle to the vacuum pressure gauge.
Note:
^ The quantity of coolant available should exceed the amount required to fill the system by about two litres in order to prevent air being sucked in.
^ An antifreeze content of -35°C corresponds to a mixture of 50:50 (antifreeze: water).
4. Place a canister with a sufficient amount of coolant and with an antifreeze content for -35 °C behind the vehicle near to the expansion tank
Note: The bleeding process is completed more quickly if the canister is positioned at roughly the same height as the coolant expansion tank.
5. Push the filler hose of the vacuum pressure gauge-5- onto the canister connection. Draw off the return line-6- of the Venturi nozzle into a second container.
Note: A hissing sound after connecting the compressed air supply is usual.
6. Connect compressed air supply to Venturi nozzle
7. Open both shutoff valves on the vacuum pressure gauge until the transparent filler hose has completely filled with coolant.
8. Close left shutoff valve on the vacuum pressure gauge and allow a vacuum to build up in the coolant circuit.
9. When there is enough vacuum in the cooling system - Vacuum established (pointer in green region), close right shutoff valve and subsequently unplug the compressed air supply.
10. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow-). The cooling system is then filled.
11. When the cooling system no longer contains a vacuum (vacuum pressure gauge shows zero), i.e. no more coolant is being sucked out of the canister, open right-hand shutoff valve.
12. Now remove the complete filling device filling device 9696 (including cap K 22).
13. If necessary, fill the coolant expansion tank with coolant up to the maximum marking and screw on the cap of the expansion tank (do not tilt).
Reworking
Subsequent work
1. Check coolant line connections and hoses for leaks.
2. Completely install rear underside panel.
Cayman:
3. Install engine cover.
4. Perform a test drive with the vehicle. Following the test drive and when the engine is still at operating temperature, accelerate briefly to greater than 6,000 rpm a number of times at idle speed in order to fully ventilate the system.
5. Check the fluid level with the aid of the marks on the expansion tank. If necessary, correct the coolant level after the engine has cooled.