Coolant: Service and Repair
WM 193817 Draining and filling coolant on DFI engines (includes bleeding)
Tools
Tools and materials
Tools
Special tools 1
Special tools 2 Filling device 9696
Information
- Pay attention to the special features in the corresponding section for vehicles with auxiliary heater. => 193817 Draining and filling coolant on DFI engines (includes bleeding) - section on "Bleeding"
Vacuum filling device components Filling device 9696
1 - - Adapter K 65 (Installed in place of the cap on the coolant reservoir.) Not shown!
2 - Hose extension FZ 100 (Fitted between K65 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
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 depressurised 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 => Work instructions after disconnecting the 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
Maintenance cover
2. Carefully open the lid on the coolant reservoir. Unscrew the lid by turning it anti-clockwise. => Lid on coolant reservoir
3. Remove the front engine guard. => 108319 Removing and installing engine cover (design cover) on DFI engines - section on "Removing"
4. Drain the cooling system => Draining cooling system. Open the lowest coolant hose, drain the coolant into a container and dispose of it according to the applicable national laws if no longer required. Allow cooling system to drain.
4.1. V6 => Detach bottom coolant hose on coolant pipe at the frame. -arrow-
4.2. V8 => Detach lower coolant hose on the radiator. To do this, undo clip on Henn coupling and pull off coupling -arrow, coolant hose viewed from above-. Refit clip on Henn coupling. If necessary, pull off coolant hoses on the oil/water heat exchanger and drain remaining coolant -1 and 2-. V8 Turbo => Remove boost pressure pipe on the right-hand side. -1-
5. Drain the rest of the coolant as required.
5.1. Screw adapter K65 onto the coolant reservoir. => Adapter on coolant reservoir
5.2. Adjust air connection (workshop connection) to 0.5 bar overpressure using a pressure reducer => Pressure reducer. Connect pressure hose to workshop connection and route it, but do not connect to the adapter K65.
5.3. Get a second worker to hold the disconnected coolant hose into the collecting container
5.4. Connect compressed air connection to adapter K65 on the coolant reservoir. Coolant shoots out of the coolant hose. Blow out cooling system.
5.5. Leave air connection connected until there are only drips emerging.
6. Refit disconnected coolant hoses.
1. If you have not already done so, screw cap adapter K65 for coolant reservoir 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 shutoff valves are closed (positioned at 90° with respect to flow direction).
4. Connect the Venturi nozzle to the vacuum pressure gauge. => Connecting Venturi nozzle to vacuum pressure gauge
Information
5. Place a canister with a sufficient amount of coolant and with an antifreeze content of -35 °C beside the vehicle close to the reservoir.
Information
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).
Information
7. Connect the compressed air supply.
8. Open both shut-off valves on the vacuum pressure gauge => Shutoff valves on vacuum pressure gauge until the transparent filler hose has completely filled with coolant.
9. Close the left shutoff valve (V1) -arrow- on the vacuum pressure gauge and allow a vacuum to build up in the coolant circuit.
Information
10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right shutoff valve (V2) and then disconnect the compressed air supply.
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 shutoff valve (V2). => Opening right shutoff valve
13. Then remove the complete filling tool (including the adapter K65).
14. If necessary, fill the coolant reservoir with coolant to the MAX marking. => MAX marking on coolant reservoir
15. If necessary, check to ensure that the cooling system is properly sealed. => Cooling system test device
16. Screw on lid on reservoir in a clockwise direction. => Lid on reservoir
17. Close the maintenance cover.
18. Re-install the complete engine guard. => 108019 Removing and installing engine guard (underbody panel) on DFI engines - section on "Installing"
19. 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.
1. Fill and bleed the vehicle as described using the vacuum filling device. => 193817 Draining and filling coolant (includes bleeding)
2. Warm engine to operating temperature ( = 90 °C).
Information
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 lid on the coolant reservoir. Unscrew the lid by turning it anti-clockwise. => Lid on coolant reservoir
7. Check coolant level and, if necessary, fill the coolant reservoir with coolant to the MAX marking. => MAX marking on coolant reservoir
8. Screw on lid on reservoir. => Lid on reservoir
9. Close the maintenance cover.