Cooling (997) Porsche 911 Carrera 997

Engine cooling

Tools

Coolant - check antifreeze and fluid level

Note. The coolant filled in at the factory is intended for lifetime cooling and, thus, need not be changed.

Scheme 1

> Only work on the coolant system when the engine is "cool".

> Wear protective gloves and goggles.

> Wear protective gloves and goggles.

> If you come into contact with coolant, wash off immediately with plenty of warm water.

> Do not mix Porsche coolant with other coolants.

> When replacing or topping up coolant, use only original Porsche coolant (see Porsche Parts Catalogue).

1. Check antifreeze content. To do this, open the lid on the coolant expansion tank and check with an anti-freeze testing device. If this is below - 35°C, correct the anti-freeze content by raising the proportion of pure coolant accordingly

Scheme 2

> Only work on the coolant system when the engine is "cool".

> Wear protective gloves and goggles.

1. Check the cooling system for leaks. To do this, apply a test pressure of approx. 1 bar and check hose connections for leakage

Scheme 3

> Clean radiator surface regularly.

> Do not use a high-pressure steam cleaner to clean it.

1. Check cooling air guides and radiator for foreign bodies such as leaves. If necessary, carefully clean the cooling air guides and radiator surfaces at the front using a vacuum cleaner with a single nozzle, see Vacuum cleaner nozzle, long crevice tool for cleaning cooling air inlet shafts NR.160 . When using high-pressure steam cleaners, the steam jets can cause additional particles of dirt to attach to the radiator surfaces and the engine can overheat due to reduced cooling performance

Scheme 4

Note. The following diagram shows the scale used by Leitenberger The scales can vary, depending on the manufacturer, observe the operating instructions Use the "ETHYLENE" scale for Porsche coolant.

1. The correct antifreeze content can be read off the ETHYLENE scale

Scheme 5

2. Using a pipette, take a sample from the coolant expansion tank. Sprinkle a few drops on the test surface of the refractometer.

Scheme 6

3. Close the light-diffusing lens. A closed film of liquid must form.

Note. The following table specifies how much coolant must be replaced by pure coolant in order to adjust the freezing point to -37 °C.

4. Hold the refractometer against a bright light source. A clear light/dark limit emerges. The point of intersection between this line and the display scale marks the freezing point of the coolant. A freezing point that is too low must be adjusted according to the following table

Preliminary work for removing air guide

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Scheme 7

1. Pull off the air guide for the middle radiator. To do this, pull the right and left rubber tabs for the air guide off the radiator -1-. Pull the top three rubber tabs up -2- and release them. Loosen the air guide around the radiator and remove it. (Scheme 7)

Scheme 8

1. Remove the air guide at the left side. To do this, remove the three fastening screws -1- and pull the air guide sideways out of the plastic tabs -2-. (Scheme 8)

Scheme 9

2. Remove the air guide on the right side in the same way as on the left. The temperature sensor must also be pulled out of the air guide from behind -arrow-. (Scheme 9)

The relevant radiator must be removed in order to remove the rear air guide.

Scheme 10

3. Remove the sheetmetal clips and washers under the radiator bracket -arrows-. To do this, release the sheetmetal clips using a suitable screwdriver and push them sideways out of the plastic pegs of the radiator. Pull the radiator from the bracket up out of the guide. (Scheme 10)

4. Disengage the rear air guide from the cooling fan. To do this, disconnect the cable plug -1- and press the plastic lock together -2-. Then, lift the air guide out of the tabs -3-. see scheme 11

Installing air guide for middle radiator

1. Fit air guide for middle radiator. Move air guide on radiator to installation position. To do this, press on the right and left rubber tabs for the air guide on the radiator -1-. Push in the top three rubber tabs -2-. Press the edge of the air guide around the radiator. Check that it is fitted correctly. see scheme 12

Installing air guide for side radiator

1. Fit rear air guide on cooling fan. To do this, push air guide into the tabs -3- and press air guide into the lock -2-. Fit cable connector -1-. see scheme 13

2. Install side radiator .

3. Fit air guide. To do this, push radiator sideways into the plastic tabs -2- and screw in 3 fastening screws -1-. (Scheme 11)

4. Fit the air guide on the right side in the same way as on the left side. In addition, push the temperature sensor into the air guide from behind -arrow-. (Scheme 11)

Subsequent work for installing air guide

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Preliminary work

1. Removing rear underside panel Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

Cayman only

Scheme 11

2. Remove engine cover --> 55 90 19 REMOVING AND INSTALLING REAR LID - AS OF MY 2005 (ALL MODELS) .

Draining coolant

Note. In order to facilitate assembly of coolant pipes and hoses smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from the Porsche Parts catalogue) Check Henn coupling O-rings and replace if necessary. Clean push-in connector and coolant hoses before assembly.

Scheme 12

> 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-. (Scheme 14)

Scheme 13

> Only work on the coolant system when the engine is "cool".

> Wear protective gloves and goggles.

> 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 ftlb +4 ftlb

Scheme 14

> Only work on the coolant system when the engine is "cool".

> Wear protective gloves and goggles.

> 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. (Scheme 16)

Scheme 15

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. (Scheme 17)

Scheme 16

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 P 9696 . 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.

Scheme 17

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).

Scheme 18

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 liters 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

Scheme 19

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. (Scheme 21)

Scheme 20

Note. A hissing sound after connecting the compressed air supply is usual.

6. Connect compressed air supply to Venturi nozzle.

Scheme 21

7. Open both shutoff valves on the vacuum pressure gauge until the transparent filler hose has completely filled with coolant.

Scheme 22

8. Close left shutoff valve on the vacuum pressure gauge and allow a vacuum to build up in the coolant circuit.

Scheme 23

9. When there is enough vacuum in the cooling system --> pointer in green region (Scheme 25), close right shutoff valve and subsequently unplug the compressed air supply. (Scheme 25)

Scheme 24

10. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow- ). The cooling system is then filled. see scheme 29

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 P 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).

Subsequent work

1. Check coolant line connections and hoses for leaks.

2. Completely install rear underside panel. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

Cayman

Scheme 25

3. Install engine cover --> 55 90 19 REMOVING AND INSTALLING REAR LID - AS OF MY 2005 (ALL MODELS) .

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.

> Do not work on fuel system if engine is hot!

> Do not smoke, avoid fire and naked flames!

> Wear fuel-resistant protective gloves and goggles.

> Attach warning sign to vehicle in a clearly visible position.

> Do not work on the engine while it is hot.

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

1. Remove air cleaner housing Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. Open cap -1- on coolant reservoir. see scheme 31

3. Place a clean container under the vehicle.

4. Drain coolant. Unscrew coolant drain plug and collect emerging coolant.

5. Re-insert drain plug with a new seal and tighten. --> Tightening torque: 15 (11 ftlb.) Nm

Note. In order to facilitate assembly of coolant pipes and hoses smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from the Porsche Parts catalogue)

6. Pull off coolant hose to coolant pump -1- and collect emerging coolant. Re-fit hose. (Scheme 27)

Removing reservoir for coolant

A - Reservoir

Scheme 26

Scheme 27

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

1. Pull off coolant hose -1- on plastic pipe. To do this, open spring band clamp -2-. Collect emerging coolant with a cloth. (Scheme 29)

2. Remove overflow hose and supply hose from radiator on coolant reservoir. Unclip supply hose from support.

Scheme 28

> Do not work on fuel system if engine is hot!

> Do not smoke, avoid fire and naked flames!

> Wear fuel-resistant protective gloves and goggles.

> Attach warning sign to vehicle in a clearly visible position.

3. Unclip fuel line on plastic holder -1- and disconnect at the rapid-action coupling -2-. Absorb emerging fuel with a cloth. Remove plastic holder on coolant reservoir. (Scheme 30)

Scheme 29

4. Disconnect line to carbon-canister line -1-. Remove coolant ventilation -2- on container. (Scheme 31)

Scheme 30

5. Remove coolant pump feeder hose on container -2-. Collect emerging coolant with a cloth, block flange. Disconnect cable plug for coolant-level indicator sensor, remove sensor carefully from container (bayonet lock). (Scheme 32)

Scheme 31

6. Unclip lines on plastic holder -1-, remove holder on fuel collection pipe and intake distributor in an upward direction. (Scheme 33)

Scheme 32

7. Unplug cable plug for cycle valve -1- on intake distributor 1-3, hall sender connector -2- and fuel injector connector -3-. Remove cable duct from fuel collection pipe and lay it down. see scheme 40

Scheme 33

8. Unscrew both M6 fastening screws -1- on fuel collection pipe and position collection pipe diagonally as close as possible on the intake distributor, securing it with tie-wraps if necessary. (Scheme 34)

9. Lower engine by approx. 40 mm; to do this, support the engine using a jack and retainer plate P 9592 . Undo and unscrew collar nuts on engine mounting. Lower engine carefully with the jack; if necessary, have a second person assist with this task.

10. Unscrew M6 collar nut for coolant container fastening to body. Pull coolant container out of holder and engine guide until it can be released in a downward direction.

11. Guide container to the rear and at an angle out of the engine compartment.

12. Absorb emerging coolant with a cloth.

Installing reservoir for coolant

1. Insert container into engine compartment, secure it in holder and guide, position and tighten M6 collar nut. --> Tightening torque: 10 (7.5 ftlb.) Nm

2. Raise engine in installation position with jack, position and tighten collar nuts on pins. Remove retainer plate. --> Tightening torque: 85 (63 ftlb.) Nm

3. Insert sensor for coolant-level indicator in container and engage cable plug.

4. Fit fuel collection pipe, position and tighten two fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

5. Reconnect cable plug for fuel injectors, hall sender and cycle valve. Position wiring harness on fuel collection pipe.

6. Clip holder into intake distributor and fuel collection pipe, secure lines.

7. Connect fuel line rapid-action coupling and clip line into holder on coolant container.

8. Connect rapid-action coupling for carbon-canister line.

Note. In order to facilitate assembly of coolant pipes and hoses smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from the Porsche Parts catalogue)

9. Fit coolant hoses and overflow hose.

1. Fill coolant and bleed system > 193817 Draining and filling coolant - chapter on "Filling" .

2. Install air cleaner housing Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

3. Perform a test drive, adjusting the coolant level in the container if necessary (note minimum/maximum marking).

1. Remove air cleaner housing Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

2. Relieve and remove drive belt Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

> Do not work on the engine while it is hot.

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

3. Drain coolant on engine > 193817 Draining and filling coolant - chapter on "Draining"

4. Remove coolant hose from reservoir to coolant pump -1-. Collect emerging coolant in a clean container. (Scheme 35)

5. Remove both catalytic converters Refer to 26 73 19 Removing and installing catalytic converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

> Support engine at all times.

6. Support engine in installation position with a transmission jack.

Scheme 34

7. Remove engine carrier Refer to 10 30 19 Removing and installing engine carrier - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

Scheme 35

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

1. Unscrew seven fastening screws (two M6 x 30 -2-, five M6 x 25 -1- ) to coolant pump, remove pump. (Scheme 37)

Scheme 36

2. Cut through seal webs -arrows- in the combination seal, remove old seal. (Scheme 38)

Installing coolant pump

1. Clean sealing face of coolant pump with solvent naphtha or acetone, remove with emery cloth if necessary and then degrease.

Scheme 37

2. Clean sealing face on crankcase with solvent naphtha or acetone. Remove any residues beforehand with an emery cloth.

Scheme 38

3. Separate new combination seal at the dot-dash line.

4. Position coolant pump with new seal on crankcase using two screws, note position of dowel sleeves.

5. Position remaining screws. The longer screws (M6 x 30) -2- are installed at the dowel sleeve position. (Scheme 40)

6. Tighten all screws equally in diagonally opposite sequence. --> Tightening torque: 10 (7.5 ftlb.) Nm

7. Position drive belt on pulley.

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

Note. In order to facilitate assembly of coolant pipes and hoses smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from the Porsche Parts catalogue)

1. Fit coolant hose.

2. Install engine carrier Refer to 10 30 19 Removing and installing engine carrier - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) . --> Tightening torque: 65 (48 ftlb.) Nm . --> Tightening torque: 10 (7.5 ftlb.) Nm

3. Move transmission jack from work area.

4. Install catalytic converters Refer to 26 73 19 Removing and installing catalytic converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

5. Fit drive belt Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

6. Install air cleaner housing Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

7. Fill coolant and bleed system > 193817 Draining and filling coolant - chapter on "Filling" .

8. Perform a test drive, adjusting the coolant level in the container if necessary (note minimum/maximum marking).

> Do not work on the engine while it is hot.

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

1. Place a clean container under the vehicle.

2. Drain coolant > 193817 Draining and filling coolant - chapter on "Draining"

3. Remove coolant hoses to coolant pump and thermostat; to do this, first open a spring band clamp for each hose.

Remove coolant regulator

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

Scheme 39

1. Remove two M6 fastening screws -1- for coolant line on crankcase. Unscrew three M6 screws on coolant regulator housing -arrow-. (Scheme 41)

Scheme 40

2. Push coolant line upward and unscrew the top fastening screw -arrow-. (Scheme 42)

3. Remove housing, take out thermostat. Collect the emerging coolant.

Scheme 41

Thermostat insert tool

Scheme 42

4. Using the assembly aid P 9627 , push the springs down and twist the sheetmetal tabs out of the holding slots, remove insert.

Installing coolant regulator

1. Clean the sealing faces of the housing and crankcase.

2. Insert thermostat insert into guide using the assembly aid P 9627 .

3. Position housing cover with new seal and thermostat on crankcase and position with four M6 fastening screws.

4. Tighten the screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

Note. In order to facilitate assembly of coolant pipes and hoses smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from the Porsche Parts catalogue)

5. Fit coolant hoses.

6. Secure coolant line on crankcase. Tighten two M6 screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

1. Fill coolant and bleed system > 193817 Draining and filling coolant - chapter on "Filling" .

2. Perform a test drive, adjusting the coolant level in the container if necessary (note minimum/maximum marking).

Preliminary work for removing middle radiator

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

> 193817 Draining and topping up with coolant - chapter on "draining"

> 192419 Removing and installing air guide - chapter on "removing"

Scheme 43

> Only work on the coolant system when the engine is "cool".

> Wear protective gloves and goggles.

> Wear protective gloves and goggles.

> If you come into contact with coolant, wash off immediately with plenty of warm water.

Note. Despite the fact that the coolant has been drained, residual amounts of coolant can still emerge at the joints during removal. Have sufficient collecting containers and cloths to hand.

1. Open the Henn coupling for the side radiator at the left side -1- and drain coolant. Remove the safety clip on the Henn coupling and disconnect the connection. Refit the safety clips immediately. see scheme 54

Note. The help of a second person is required in order to remove and install the middle radiator.

2. Remove the two fastening screws at the top -3- and two fastening nuts at the bottom -2- of the radiator bracket. Get a second person to help you lift the radiator together with the bracket and remove the Henn coupling for the right side radiator. Refit wire clip immediately. Remove radiator, complete with bracket. see scheme 54

3. Remove the retaining plate under the bracket by unscrewing two fastening screws -4- and remove the middle radiator from the bracket. see scheme 54

Installing middle radiator

1. Insert middle radiator into bracket. Make sure that the rubber sleeves of the radiator are inserted into the corresponding cutout on the bracket or retaining bracket. Screw in two fastening screws on retaining bracket --> Tightening torque: 10 (7.5) Nm (ftlb.) .

Note. The help of a second person is required in order to remove and install the middle radiator.

2. Get a helper to assist in moving the middle radiator into installation position and connect the two side Henn couplings for the coolant hoses until they click into place. Check that the Henn couplings are engaged correctly. Screw two fastening screws at the top -3- and two fastening nuts at the bottom -2- of the radiator bracket hand-tight. see scheme 54

3. Tighten all fastening screws and fastening nuts on radiator bracket --> Tightening torque: 23 (17) Nm (ftlb.) .

4. Check that middle radiator is in the correct installation position.

Subsequent work for installing middle radiator

> 192419 Removing and installing air guide - chapter on "installing"

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4) .

> 193817 Draining and topping up with coolant - chapter on "topping up"

Poses Online

See also:
• 63 15 19 Removing and installing front spoiler - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models)
• 55 90 19 REMOVING AND INSTALLING REAR LID - AS OF MY 2005 (ALL MODELS)
• 24 25 19 Removing and installing air cleaner housing - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 13 78 19 Removing and installing drive belt - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 26 73 19 Removing and installing catalytic converter - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• 10 30 19 Removing and installing engine carrier - as of MY 2005 (Carrera 2, Carrera 2S, Cabrio 2, Cabrio 2S, Carrera 4, Cabrio 4)
• Vacuum cleaner nozzle, long crevice tool for cleaning cooling air inlet shafts NR.160