193817 Draining and filling in coolant
WM 193817 Draining and filling in coolant
Tools
Preliminary work
1. Remove rear underbody panel -> 519419 Removing and installing rear cover - Removing 519419 Removing and Installing Cover for Rear Underbody.
Draining coolant
WARNING
Hot pressurised coolant.
- Danger of scalding and burning.
-> Only work on the coolant system when the engine is "cool".
-> Wear protective clothes, gloves and goggles.
Information
- In all Cayman vehicles and in Boxster vehicles from MY 2007, the coolant expansion tank is located in the engine compartment.
- Testing and inspection work can be performed via the opening in the service tray (right).
- Filling and bleeding work are performed on the coolant expansion tank.
1. Open cap on the coolant expansion tank or in the service tray.
Opening cap (example)
WARNING
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.
-> Wear protective gloves and goggles.
-> If you come into contact with coolant, wash off immediately with plenty of warm water.
Information
- Check Henn coupling O-rings and replace if necessary.
- Clean plug connections and coolant hoses before assembly.
- Remove stoppers before fitting the coolant lines and hoses.
Information
To facilitate assembly of coolant pipes and hoses, smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available in 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. ; ;
"Henn coupling" in coolant hoses
WARNING
Coolant is corrosive and hazardous to health.
- Risk of skin and eye irritation.
-> Wear protective gloves and goggles.
-> If you come into contact with coolant, wash off immediately with plenty of warm water.
Information
To facilitate assembly of coolant pipes and hoses, smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available in 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. ;
Water pump coolant hoses, thermostat, heater
4. Remove heating hoses on the vehicle underbody -5-. Close the pipes with hose clamps 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, push them back on and fit the clamps. Check that the hoses are firmly in place.
Filling in coolant
Filling coolant (includes bleeding)
Information
The process of filling and bleeding the cooling system is performed using the special tool filling device 9696.
Information
- In all Cayman vehicles and in Boxster vehicles from MY 2007, the coolant expansion tank is located in the engine compartment.
- Testing and inspection work can be performed via the opening in the service tray (right).
- Filling and bleeding work are performed on the coolant expansion tank.
1. Fit the vehicle protective covers.
2. Protect the luggage compartment against soiling with a cover.
3. Screw cap adapter for coolant expansion tank (K22) onto the tank and attach flexible extension (Fz100) to the cap.
Connecting K22 adapter (view of Boxster)
Connect K22 adapter (Cayman and Boxster from MY 2007)
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).
5. Connect the Venturi nozzle to the vacuum pressure gauge.
Venturi nozzle on vacuum pressure gauge
Information
- 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).
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
Information
- The bleeding process is completed more quickly if the canister is positioned at the same height as the coolant reservoir.
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.
Special canister filling tool
Information
- A hissing sound after connecting the compressed air supply is normal.
8. Connect compressed air supply to Venturi nozzle
Compressed air supply on Venturi nozzle
9. Open both shutoff valves on the vacuum pressure gauge until the transparent filler hose has completely filled with coolant.
Shutoff valves open
10. Close left shutoff valve on the vacuum pressure gauge -arrow- and allow a vacuum to build up in the coolant circuit.
Left-hand shutoff valve closed
Information
- 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.
Vacuum established (pointer in green region)
12. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow- ). The cooling system is then filled.
Left-hand shutoff valve open - right-hand valve (arrow) closed
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 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).
Tighten cap (view of Boxster)
Subsequent work
1. Check coolant line connections and hoses for leaks.
2. Completely install rear underbody panel. -> 519419 Removing and installing rear cover - Installing 519419 Removing and Installing Cover for Rear Underbody
3. Test drive 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.
4. 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.