Coolant: Service and Repair
WM 193817 Draining and filling in coolant (includes bleeding)
Tools and materials
Special tools
Special tools 1
-A- Flexible screwdriver a/f 7 (for loosening and tightening screw-type hose clamps) Flexible screwdriver a/f 7 NR.73-1
-B- Antifreeze tester (for checking the antifreeze content in the cooling system. The design can deviate from that shown in the picture.)
-C- Spring band clamp pliers (for opening and closing spring band clamps) Assembly tools for spring band clamps NR.72
Special tools 2 Filling device 9696
-1- - Canister (canister with lifting tube, 30-liter capacity, with volume scale)
-2- - Hose extension
-3- - Adapter K 22 (supplied with radiator vacuum filling device)
-4- - Venturi nozzle (supplied with radiator vacuum filling device)
-5- - Adapter K 60 (supplied with radiator vacuum filling device)
-6- - Pressure gauge (supplied with radiator vacuum filling device)
Information
Components of the radiator vacuum filling device
Information:
Pay attention to the special features in the corresponding chapter for vehicles with auxiliary heater.
Vacuum filling device components Filling device 9696
-1- - Adapter K 22 (installed in place of the cap on the coolant reservoir.)
-2- - Hose extension FZ 100 (installed between K22 and KVB 01.)
-3- - KVB 01 (vacuum pressure gauge with two shut-off valves)
-V1- - Shut-off valve V1 (shutoff valve for the filler hose.)
-V2- - Shut-off valve V2 (shutoff valve for the filler hose.)
-4- - Venturi nozzle (a vacuum is produced in this component by means of compressed air. A pressure of between 6 and 10 bar must be present.)
-5- - Filler hose (the cooling system is refilled via this hose.)
-6- - Return lines (the compressed air and extracted coolant are drawn off via this hose.)
Draining coolant
Draining coolant
Caution:
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
- Swallowing coolant additives and cleaning liquids must be urgently avoided.
- Do not consume any food or drink while working (danger of accidental mixing).
- If swallowed, observe the warning information on the containers and contact a doctor. If necessary, show the doctor the warning information on the packaging.
Caution:
Danger of scalding with hot coolant!
- Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
- The cooling system must be depressurized before being opened.
- Allow engine to cool down.
Danger:
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
- The power supply to the fans must be disconnected before starting work on the radiator, radiator fans or belt drive. Disconnect the fuse carrier or battery.
- Allow engine to cool down.
Caution:
Risk of damaging the cooling system!
- Do not relieve the system pressure of the cooling system and then run the engine.
- Relieving the system pressure and subsequently starting the engine can cause severe damage to components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling system to cool down before starting the engine again.
Information:
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50 (coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
1. Open maintenance cover.
Maintenance cover
2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
Cap on coolant reservoir
3. Open cap on the reservoir and remove.
4. Remove engine guard.
Engine guard
5. Release the front apron on the underside.
Front apron fastening screws
6. Remove the support plate under the radiator. To do this, loosen the 4 fastening screws.
Support plate fastening screws
7. Drain cooling system. If present, remove the drain plug from the radiator, otherwise open the lowest coolant hose on the radiator, and drain the coolant into a container and dispose of it according to the applicable national laws if no longer required.
Draining cooling system
8. Fit a new drain plug on the radiator and tighten it. If removed, fasten coolant hose.
9. Install the support plate under the radiator. Tighten the four fastening screws. - Tightening torque: 17 ftlb.
Support plate fastening screws
Filling the cooling system (includes bleeding)
Filling cooling system (includes bleeding)
1. Screw the cap adapter for the coolant reservoir (K 60) onto the reservoir.
2. Connect the flexible extension (Fz 100) to the cap.
3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing so, ensure that both shut-off valves are closed (positioned at 90° to flow direction).
4. Connect the Venturi nozzle to the vacuum pressure gauge.
Connecting the Venturi nozzle to the vacuum pressure gauge
Information:
The coolant amount provided must be approx. 2 liters more than the amount to be filled in.
Because differing quantities of coolant can drain away for different types of repairs, the filling capacities can vary greatly. Recommendation: To be on the safe side, fill the canister to 30 l, then bleed the cooling system. The difference after bleeding is the coolant quantity that was sucked in. Observe volume scale on the canister.
An antifreeze content of -35°C corresponds to a mixture of 50 : 50 (antifreeze : water).
5. Place a canister with a sufficient amount of coolant and with an antifreeze content of -35°C beside the vehicle near the reservoir.
Information:
The bleeding process is completed more quickly if the canister is positioned at roughly the same height as the coolant expansion tank.
6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Lay the return line -6- from the Venturi nozzle to a second container (bucket).
Vacuum filling device components
Information:
A hissing sound after connecting the compressed air supply is usual.
7. Connect the compressed air supply.
Connecting the compressed air supply
8. Open both shut-off valves on the vacuum pressure gauge until the transparent filler hose -5- has completely filled with coolant.
Shut-off valves on the vacuum pressure gauge
9. Close the left shut-off valve (V1) on the vacuum pressure gauge and allow a vacuum to build up in the cooling system.
Closing the left shut-off valve (V1)
Information:
If no vacuum is generated (the pointer does not move to the green area), there is a leak in the cooling system.
If a vacuum is still not established, there is a blockage in the tool. Clean the device, use clean compressed air.
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.
10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right shut-off valve (V2) and then disconnect the compressed air supply.
When there is sufficient vacuum, close the right shut-off valve (V2)
11. Re-open the left shut-off valve (V1) on the vacuum pressure gauge. The cooling system is then filled.
12. When there is no trace of vacuum present or the coolant is no longer drawn from the canister, open the right shut-off valve (V2).
Opening right shut-off valve
13. Then remove the complete filling tool (including the cap K 60).
14. If necessary, fill the coolant reservoir with coolant to the maximum marking.
Maximum marking for coolant reservoir
Information:
If necessary, the system can be checked for leaks.
Cooling system test device
15. Screw on the cover of the reservoir in a clockwise direction.
Reservoir cap
16. Close the maintenance cover.
17. Re-install the complete engine guard.
18. Conduct a test drive with the vehicle, check the fluid level in the reservoir after the cooling system has cooled again and, if necessary, fill up to the max marking with coolant.
Bleeding vehicles with auxiliary heater
Bleeding vehicles with auxiliary heater
1. Fill and bleed the vehicle as described in the previous chapter using the vacuum filling device.
2. Warm engine to operating temperature (90°C).
Information:
Do not activate the 2/3 directional-control valve with the Porsche System Tester above 1500 rpm.
Activate the 2/3 directional-control valve with the Porsche System Tester below 1500 rpm.
3. Operate engine for 5 minutes with changing engine speeds. When doing this, run the engine for 10 seconds in idle and then for 10 seconds at 4,000 rpm. In the speed transition from higher engine speeds (1500 to 4000 rpm) to idle (approx. 600), the directional-control valve should be activated with the Porsche System Tester below 1500 rpm. Note that the 2/3 directional-control valve is not activated with the Porsche System Tester above 1500 rpm.
4. Let the vehicle cool down.
5. Open maintenance cover.
Maintenance cover
6. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
Cap on coolant reservoir
7. Check coolant level and, if necessary, fill the coolant reservoir with coolant to the maximum marking.
Maximum marking for coolant reservoir
8. Screw on the cover of the reservoir.
Reservoir cap
9. Close the maintenance cover.