Helpful ReplyCoolant leak repaired..

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Contraband
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RE: Coolant leak repaired.. 2015/02/18 22:05:05 (permalink)
The hoses are straightforward to replace. The problem is, 3 hours of labour could be up to £450.
If you are handy-ish with the spanners do it yourself. It's good fun.
Chris_in_the_UK
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RE: Coolant leak repaired.. 2015/02/18 23:37:35 (permalink) ☄ Helpfulby chaz1 2017/05/14 19:10:54
This was what happened when I did this over summer on my Cayman S - Hopefully this may be helpful or give some insight to a couple of issues I had recently and how to solve them.

Anyway......

The car is knocking on the door of 10 years old and apart from service stuff, pretty much everything else is original.

The usual debris/detritus issue was encountered once the bumper was removed.



Aircon rads off - they will be replaced, along with the dryer - with new O rings of course.







Radiator removal requires a few stuff to be disconnected (obviously!) and this is where the troubles begin.....

I had to cut the first one after the retaining clip was removed so I could get a proper grip of the metal sleeve - it took a while to persuade out of the socket and here is why....



Here is where it came from (Offside), you will notice that the lower socket is a plastic tee - the upper one is an aluminium tube which I suspected was going to be a whole lot more difficult!.

After liberal use of Plus Gas and ever increasing application of cunning/brute force it was obvious that the only thing that was happening was the distortion of the socket.





The nearside was in the same state and neither could be separated from the aluminium coolant pipes that run across the front of the car.

So all in all, a very frustrating day - new pipes were easy to get from my OPC - when I rang to order them it became clear during the discussion that this is a common problem across the Cayman/Boxster/997. What appears to be a slight amount of corrosion around the hose/socket joint which will probably be communicated as an 'advisory' (like mine was) can in fact be hiding what I found. My OPC (Leeds) keeps the pipes in stock (which kind of confirms that it is a common problem IMO).

Rgds.
Chris
keiththo
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RE: Coolant leak repaired.. 2015/02/19 10:00:08 (permalink)
Thanks very much Chris, very useful. Sadly I no longer have a garage so am not going to attempt this in the street. I will try some indies to see if they will charge significantly less than £500 !
Keith

2015 Cayman 2.7
Previously owned:
944 2.7,
964 Carrera 4 Targa,
Boxster 987.1
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Re: Coolant leak repaired.. 2015/08/06 15:18:21 (permalink)
Hi Contraband, 
Very helpful post.
Just been told and shown I have the same problem. They said that this pipe runs the length of the car and it cost around £470.😕😕 I guess that steel pipe that's it's attached to, and after reading your post it seems it's a job I can do myself. Hopefully the main pipe is intact and I'll have the same result as you.
Cheers
Kfrog
 
Contraband
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Re: Coolant leak repaired.. 2015/08/06 22:12:34 (permalink)
Kfrog.. The pipe I replaced goes into a plastic fitting. The fitting is attached to a metal pipe that runs the length of the car. It really is a straightforward job but if the fitting is badly corroded and expanded it may be that you have to dig it out of the plastic fitting.
 
Archie.
Buddy
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Re: Coolant leak repaired.. 2015/08/20 08:04:25 (permalink)

 
I vacuum cleaned the intakes of my Gen1 regularly when dry to prevent the build up of the detritus but as I recently sold my Gen1 after almost 8 yrs I still have a pair of home made grilles which I used each autumn through to spring to reduce the rubbish and wet leaf intake.
 
They attach using small tie-wraps which are well disguised by the black mesh If anyone would like these get in touch.
post edited by Buddy - 2015/08/20 08:23:41

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Kevan
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Cayman S Gen2 PDK Amethyst Metallic
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Contraband
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Re: Coolant leak repaired.. 2015/08/20 08:51:56 (permalink)
Oh, I'm interested Kevan...
send me an email please...
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Re: RE: Coolant leak repaired.. 2015/10/04 07:07:03 (permalink)
Some really helpful tips on this thread
 
post edited by bear911lancs - 2015/10/04 07:16:29

997.1 S2 Carrera 2005 speed yellow
ex 911 3.2 Carrera 1987 guards red
ex 944 1986 guards red


stephenbailey
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Re: Coolant leak repaired.. 2016/01/04 19:20:33 (permalink) ☄ Helpfulby Tony Daniel 2016/01/25 16:29:52
Hi Guys
Just an update following on from this thread:
I undertook the same job of replacing the 4 radiator hoses (approx £80 for the 4 including clips from opc)
When removing they were so corroded that I damaged the two aluminium pipes which two of the hoses connect to
I purchased 2 new pipes from my local opc (approx £60 for both) 
The first task to undertake is to lower the front sub frame (Due to the pipes crossing over one another so close to the steering rack). The subframe bolts were released part way and I used a trolley jack to support the front cross member so as to make it easier to line up when re fastening. 
There is a plastic clip on both sides of the car just beyond where the hoses attach (accessible through the wheel arch) which holds the two pipes together and in place, this is a single bolt which needs to be removed
Porsche make the job very easy by labelling each pipe left & right and also put a small blue mark on each pipe to line up with the bottom of each hose, which is helpful when your laid upside down under the car. The pipes take a bit of jiggling to line up and a second pair of hands is a must. I found it easier to thread the drivers side pipe through first, this was done through the wheel arch. I did not connect the pipe fully to the small rubber connection hose until the second pipe was threaded through, then both were connected under the vehicle on each side.
The plastic clips were then re attached either side to hold both pipes in position
The sub frame was then raised and re connected and the 4 radiator hoses attatched. 
 
I hope this helps anyone undertaking this task in the future
(next job: sort the headlamp washers)
 
Many Thanks
Steve
 
 
Cayman S 2006
Derek H
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Re: Coolant leak repaired.. 2016/01/11 06:43:44 (permalink)
Thanks for the info Steve.  How many hours work would you estimate this took?
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Re: Coolant leak repaired.. 2016/01/11 19:18:07 (permalink)
Hi Derek
I think you could master the whole job in a day & a bit (depending on brew breaks), Maybe even a day if you crack on, that's replacing  hoses & alloy pipes, always takes longer when you've not done it before. If I  was to undertake again i would put a full weekend aside but then I'm the type that removes a wheelarch liner & cleans everything else while I'm in there
I was working from axle stands which extends the time & also working around my own work
A lot of time is spent stripping everything down, re connecting, bleeding the system through etc
Although I got the car up to temperature & everything's bone dry im  not going to put the plastic covers back on until I've taken for a run in the dry just to double check everything is ok
 
I hope this helps you & feel free to ask anything you are struggling with 
Gladly give you a lift if your anywhere near the South Lakes
 
cheers 
 
Steve
 
 
 
Derek H
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Re: Coolant leak repaired.. 2016/01/12 06:40:41 (permalink)
Steve, is there a potential corrosion problem where the hoses connect to the rads or are the rad inlet/outlets plastic?  
 
Many thanks for the offer of help but I'm in Bristol!
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Re: Coolant leak repaired.. 2016/01/12 17:41:44 (permalink) ☄ Helpfulby chaz1 2017/05/14 19:10:39
Hi Derek
Yes, your correct, the hoses attatch to a plastic fitting which in turn attatches  to the rads
Due to this & the fact they are covered by the wheelarch liner there was no corrosion on mine at all, they just pulled straight out
 
cheers
 
steve
post edited by stephenbailey - 2016/01/12 17:43:04
Tony Daniel
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Re: Coolant leak repaired.. 2016/01/25 16:29:04 (permalink) ☄ Helpfulby chaz1 2017/05/14 19:10:37
The corrosion on these pipes must be a design fault, the corrosion only seems to occur between the steel collars and the aluminium cross pipes, the steel to plastic looks fine.
My local independent garage says its a very common problem and wants £750 to replace the 2 aluminium pipes and the 4 hoses, reading Steve's post it seems worth attempting myself.
Has anybody any ideas as what to coat the steel collars with to help stop them reacting with the aluminium again.
stephenbailey
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Re: Coolant leak repaired.. 2016/01/26 07:18:53 (permalink) ☄ Helpfulby chaz1 2017/05/14 19:10:42
Hi Tony
I think someone commented once about loosening them off & turning the hose every couple of years to keep them corrosion free
Good luck with the job
Steve
 
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Re: Coolant leak repaired.. 2016/01/26 17:16:46 (permalink)
Tony Daniel
Has anybody any ideas as what to coat the steel collars with to help stop them reacting with the aluminium again.


If these are external surfaces then copper grease my help or a heavy duty gaffer tape.

Tony
1998 996 Carrera 4 - Ocean Blue
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Tony Daniel
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Re: Coolant leak repaired.. 2016/01/27 18:00:05 (permalink)
I gave myself a headache yesterday reading up about steel on aluminium corrosion, and found copper even the grease may make it worse !  PTFE tape might be a better idea than gaffer tape and stop the 2 metals reacting. Hopefully Porsche have now started properly zinc plating the steel collars which will help.
I also found a product called XCP rust blocker which I might give a try. 
http://carpartsandaccessoriescentre.co.uk/xcp-rust-blocker-high-performance-rust-protection-500ml/
 
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Re: RE: Coolant leak repaired.. 2016/03/04 12:14:48 (permalink)
I am not a club member, but I noticed the cost of coolant hose change in these articles. I have Changed the front alloy pipes and rubber hoses on my 2008 cayman 102,000 miles, two years ago, and it was a real time consumer, every thing was rusty or corroded and seized. The parts plus a-freeze do add up! so even a third of my time taken at Porsche labour rates would have been a shocker. I cleaned out the outside of rad cores at the same time.PS, maybe don't buy a car that has lived by the coast.
Mark.
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Re: Coolant leak repaired.. 2016/03/09 14:35:17 (permalink)
Tony Daniel
I gave myself a headache yesterday reading up about steel on aluminium corrosion, and found copper even the grease may make it worse !  PTFE tape might be a better idea than gaffer tape and stop the 2 metals reacting. Hopefully Porsche have now started properly zinc plating the steel collars which will help.
I also found a product called XCP rust blocker which I might give a try. 
http://carpartsandaccessoriescentre.co.uk/xcp-rust-blocker-high-performance-rust-protection-500ml/
 


Sorry to revise this thread, but found a product that will deal with electrolytic corrosion called Duralac developed for aerospace and marine applications. I know the 996.1 and 997 suffer problems with door and bonnet shuts corroding bodywork, and this may help your situation as well for future reference at least.

Tony
1998 996 Carrera 4 - Ocean Blue
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clubsport
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Re: Coolant leak repaired.. 2016/03/09 20:17:03 (permalink) ☄ Helpfulby Tony Daniel 2016/03/21 14:56:38
wibble
Tony Daniel
Has anybody any ideas as what to coat the steel collars with to help stop them reacting with the aluminium again.


If these are external surfaces then copper grease my help or a heavy duty gaffer tape.




I haven't done this specific job, but on other classics, (Elise and Morgan) where 2 potentially corrosive metals come into contact, I have used Duralac anti corrosive jointing compound with good results.
 
This is the Duralac, just the first listing I found, I am not selling or have any connection with them, just a customer.
 
http://www.ebay.co.uk/itm...abc:g:s0UAAOSwuAVWucaj
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