Cooling Porsche Boxster S 987

Tools

Coolant - check antifreeze and fluid level

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

> Wear protective gloves and goggles.

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

Note. On Cayman vehicles, the coolant reservoir is located in the engine compartment. Testing and inspection work are performed via an opening in the service tray (right). Filling and bleeding procedures are performed on the coolant reservoir.

Scheme 1

1. Open cap on coolant expansion tank.

Scheme 2

Cayman service tray

Scheme 3

> 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).

2. Check antifreeze content with a commercially available antifreeze tester. If this is below - 35°C, correct the anti-freeze content by raising the proportion of pure coolant accordingly.

Scheme 4

3. Screw on cap and tighten it. Do not tilt lid.

Scheme 5

> 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 . If a high-pressure steam cleaner is used, the steam jets can cause additional particles of dirt to attach to the radiator surface and the cooling vanes can be bent. The engine becomes overheated due to lack of cooling performance.

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

> Wear protective gloves and goggles.

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

Note. On Cayman vehicles, the coolant reservoir is located in the engine compartment. Testing and inspection work are performed via an opening in the service tray (right). Filling and bleeding procedures are performed on the coolant reservoir.

1. Open cap on coolant expansion tank.

Cayman service tray

> 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).

2. Check antifreeze content with a commercially available antifreeze tester. If this is below - 35°C, correct the anti-freeze content by raising the proportion of pure coolant accordingly.

3. Screw on cap and tighten it. Do not tilt lid.

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

> Wear protective gloves and goggles.

1. Open cap on coolant expansion tank.

Scheme 6

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

3. Screw on cap and tighten it. Do not tilt lid.

> 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 . If a high-pressure steam cleaner is used, the steam jets can cause additional particles of dirt to attach to the radiator surface and the cooling vanes can be bent. The engine becomes overheated due to lack of cooling performance.

Preliminary work for removing air guide

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models) .

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. > 197019 Removing and installing radiator - section on "Removing"

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 18

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 19

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 20

2. Install side radiator > 197019 Removing and installing radiator - chapter on "installing" .

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 (All Models) .

1. Disconnect ground lead of battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .

> Raise the vehicle at the prescribed jacking points.

2. Raise the vehicle at the prescribed jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .

3. Remove front right wheel. Use special tool socket wrench insert P 300 to avoid damage to the rim.

4. Remove right front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .

1. Unclip vent line -1- from the bracket and set aside. see scheme 23

Scheme 11

2. Unscrew the Torx screw (M6 x 16) -2-. see scheme 23

3. Pull out control unit for cooling air control to the rear.

Scheme 12

4. Release and disconnect cable plug -arrows-. (Scheme 13)

5. Unscrew two M6 hexagon nuts on the support and take off the control unit.

1. Position control unit in support and tighten with two M6 hexagon nuts. --> Tightening torque: 10 (7.5 ftlb.) Nm

2. Push on cable plug -arrows-. see scheme 25

Scheme 13

3. Insert control unit into the retaining lug -arrow-. (Scheme 14)

4. Clip vent line -1- into the bracket. see scheme 27

5. Screw in the Torx screw (M6 x 16) -2-. --> Tightening torque: 10 (7.5 ftlb.) Nm. see scheme 27

1. Install right front wheel housing liner Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .

2. Install front right wheel. Use special tool socket wrench insert P 300 to avoid damage to the rim.

3. Connect the battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .

4. Read out fault memory and correct any faults that are present. Erase fault memory Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models) .

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 14

2. Remove engine cover Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .

Draining coolant

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

> Wear protective gloves and goggles.

Note. On Cayman vehicles, the coolant reservoir is located in the engine compartment. Testing and inspection work are performed via an opening in the service tray (right). Filling and bleeding procedures are performed on the coolant reservoir.

1. Open cap on expansion tank.

Scheme 15

> Wear protective gloves and goggles.

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

Note. Check Henn coupling O-rings and replace if necessary. Clean push-in connector and coolant hoses before assembly.

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)

2. Remove inlet and outlet hoses from radiators Do this by pulling off the spring clips for the two Henn couplings -2- and pulling the hoses away from the coolant pipes -3-. Collect coolant in a clean container. After draining the coolant, insert the clamps in the correct position in the couplings and connect the hoses. The connection should audibly snap into place. Check correct positioning once again by pulling on the hoses. (Scheme 17)

Scheme 16

> Wear protective gloves and goggles.

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

3. Pull off spring band clamp -1- on supply hose to water pump -2-. Open spring band clamp -3- on thermostat hose and pull off hose -4-. Collect draining coolant in a clean container. Refit coolant hoses. (Scheme 18)

4. Remove heating hoses on underside of car -5-. Secure the pipes with hose clips and then open the spring band clamps. Remove both hoses and slowly open hose clamps. 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. (Scheme 18)

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 . On Cayman vehicles, the coolant reservoir is located in the engine compartment. Testing and inspection work are performed via an opening in the service tray (right). Filling and bleeding procedures are performed on the coolant reservoir.

1. Fit the vehicle protective covers.

2. Protect the luggage compartment against soiling with a cover.

Scheme 17

3. Screw cap adapter for coolant expansion tank (K22) onto the tank and attach flexible extension (Fz100) to the cap.

Scheme 18

4. 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 19

5. 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).

6. 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 20

Note. The bleeding process is completed more quickly if the canister is positioned at roughly the same height as the coolant expansion tank.

7. 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 22)

Scheme 21

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

8. Connect compressed air supply to Venturi nozzle

Scheme 22

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

Scheme 23

10. Close left shutoff valve on the vacuum pressure gauge -arrow- and allow a vacuum to build up in the coolant circuit. (Scheme 25)

Scheme 24

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.

11. 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. see scheme 39

Scheme 25

12. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow- ). The cooling system is then filled. (Scheme 26)

13. 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.

14. Now remove the complete filling device filling device P 9696 (including cap K 22).

15. 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 26

3. Install engine cover Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .

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.

Preliminary work for removing coolant pump

1. Place protective covers on the vehicle to avoid damaging the body.

2. Remove drive belt Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .

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

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

Removing coolant pump

> Raise the vehicle at the prescribed jacking points.

> 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.

Scheme 27

1. Open spring band clamps -1, 4- then loosen and pull off coolant hoses -2, 3-. (Scheme 29)

Scheme 28

2. Unscrew seven Torx screws, two M6 x 30 and five M6 x 25 -arrows-. see scheme 44

3. Remove coolant pump.

Installing coolant pump

1. Carefully remove remains of gasket from sealing faces; do not use sharp-edged tools.

Scheme 29

2. Fit new seal on the coolant pump.

3. Fit coolant pump to crankcase and secure with seven Torx screws, two M6 x 30 and five M6 x 25. Tighten screws --> Tightening torque: 7.5 ftlb. .

4. Coat inside of coolant hoses with Kluber Plus (obtainable from Porsche Parts Catalogue), push onto the connection pieces and position spring band clamps -1, 4-. (Scheme 31)

Subsequent work for installing coolant pump

1. Install drive belt Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .

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

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

4. Remove protective covers.

Preliminary work for removing coolant regulator (thermostat)

> Raise the vehicle at the prescribed jacking points.

1. Place protective covers on the vehicle to avoid damaging the body.

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

3. Drain coolant > 193817 Draining and filling in coolant - section on "Draining"

Removing coolant regulator (thermostat)

> 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.

1. Loosen spring band clamp -1-, then loosen and pull off hose -2-. see scheme 48

Scheme 30

2. Remove thermostat housing by unscrewing the four Torx screws (M6 x 20) -Arrows-. see scheme 48

Scheme 31

3. Position special tool assembly aid P 9627 and remove thermostat -1- by simultaneously pressing and twisting. (Scheme 32)

Installing coolant regulator (thermostat)

1. Carefully remove remains of gasket from sealing faces. Do not use sharp-edged tools.

2. Fit thermostat using assembly aid P 9627 .

3. Fit thermostat housing with a new gasket by screwing in the four Torx screws (M6 x 20) -arrows- and tightening evenly. --> Tightening torque: 7.5 ftlb.. (Scheme 33)

4. Coat inside of coolant hose -2- with Kluber Plus (obtainable from Porsche Parts Catalogue) and push onto housing connection piece. Position spring band clamp -1-. (Scheme 33)

Subsequent work for installing coolant regulator (thermostat)

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

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

Preliminary work for removing radiator

Refer to 50 56 19 REMOVING AND INSTALLING FRONT WHEEL HOUSING LINER - AS OF MY 2005 (ALL MODELS) .

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models) .

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

1. Remove air guides in front of radiator > 192419 Removing and installing air guide - chapter on "removing" [987310 987311 987320 987321] .

Note. The air-conditioning condenser remains in the vehicle. The air-conditioning system is not opened.

2. Detach air-conditioning condenser from side radiator and allow it to hang freely. To do this, remove hexagon-head sheetmetal screw between air-conditioning condenser and side radiator and pull air-conditioning condenser out of side brackets.

Removing radiator

Installation Location

Scheme 32

Scheme 33

1. Remove the vent line at the top of the side radiator. To do this, press the lock and pull the line off the support -1-. Pull the vent line out of the holder -2-. (Scheme 35)

Scheme 34

2. Remove cable plug from fan motor -arrow-. To do this, press cable plug together (relieve plug), open the release and disconnect the cable plug. (Scheme 36)

Scheme 35

3. Remove M6 x 16 fastening screw (outer Torx) on hose holder -arrow-. (Scheme 37)

Scheme 36

> 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.

4. Disconnect the two coolant hoses from the supports for the side radiator -arrows-. To do this, loosen the spring-band clamps from the front and push them on to the supports. (Scheme 38)

Scheme 37

5. Open up the coolant hoses at the supports using a screwdriver and allow the coolant hoses to drain -arrow-. Pull coolant hoses off the supports. (Scheme 39)

Scheme 38

6. Remove M8 x 25 fastening screw on bracket from below at the body -arrow-. see scheme 57

Scheme 39

7. Undo two M8 fastening nuts on the bracket in the wheel housing at the side wall -arrows-. Carefully remove side radiator complete with bracket to the side. Collect remaining coolant from the hoses and side radiator. Air-conditioning condenser remains in installation position. (Scheme 40)

8. When the side radiator is removed, remove the sheetmetal clips and washers for the bracket -arrows-. Carefully pull the side radiator upwards out of the bracket. see scheme 59

Scheme 40

9. Remove two hexagon-head sheetmetal screws at the side -1- and lift cooling fan housing with rear air guide out of the tabs on the side radiator -2-. see scheme 60

Installing radiator

Note. The air-conditioning condenser remains in the vehicle. The air-conditioning system is not opened.

Installation Location

1. Fit cooling fan housing with rear air guide on side radiator. To do this, push side tabs of cooling fan housing into the brackets for the side radiator -2-, move housing into installation position and fit with two fastening screws -1-. see scheme 62

2. Push radiator module into the radiator bracket. Make sure that the radiator is positioned correctly in the side guide and in the lower bores. Fit washers and sheetmetal clips on the lower fastening pins of the radiator in such a way that the sheetmetal clips engage correctly into the pins -arrows-. see scheme 63

3. Move side radiator with bracket into installation position. Make sure that the hose holder for the coolant hoses is inserted correctly into the side bracket. Push side radiator with bracket on to the studs on the side member and insert fastening screw M6 x 16 (outer Torx) for the hose holder -arrow-. see scheme 64

4. Position the M8 fastening nuts on the body studs -arrows-. see scheme 65

5. Fit fastening screws to the body from below --> Tightening torque: 23 (17) Nm (ftlb.) -arrow-. see scheme 66

6. Tighten the fastening nuts on the body studs --> Tightening torque: 23 (17) Nm (ftlb.) . Tighten fastening screw M6 x 16 (outer Torx) for hose holder --> Tightening torque: 10 (7.5) Nm (ftlb.) .

7. Push spring band clamps on to radiator flanges and fit radiator hoses to the flanges. Move engaged spring band clamps into installation position and loosen using a water-pump pliers (use a screwdriver as well, if necessary) and then fasten again -arrows-. see scheme 67

8. Fit radiator vent line to the flange -1- and clip vent line into the plastic holder -2-. (Scheme 41)

9. Connect cable plug for fan motor -arrow-. (Scheme 42)

Subsequent work for installing radiator

1. Fit air guide in front of radiator > 192419 Removing and installing air guide - chapter on "installing" [987310 987311 987320 987321] .

Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .

Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models) .

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

Preliminary work for removing coolant temperature sensor

1. Place protective covers on the vehicle to avoid damaging the body.

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

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

Removing coolant temperature sensor

> Raise the vehicle at the prescribed jacking points.

> 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.

1. Release and disconnect cable plug -1-. see scheme 70

Scheme 41

2. Remove safety clip -2-. see scheme 70

3. Pull coolant temperature sensor from coolant guide housing

Scheme 42

1. Replace O-Ring -arrow- with a new one and lightly smear with Kluber Plus (available from Porsche Parts Catalogue). see scheme 71

2. Insert coolant temperature sensor into coolant guide housing. Ensure correct seating of the O-ring.

3. Push on safety clip -2-. see scheme 72

4. Push on cable plug -1-. see scheme 72

Subsequent work for installing coolant temperature sensor

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

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

3. Remove protective covers.

Poses Online

See also:
• 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models)
• 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS)
• 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS)
• 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models)
• 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models)
• 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models)
• 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models)
• Vacuum cleaner nozzle, long crevice tool for cleaning cooling air inlet shafts NR.160