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Porsche 911 Carrera Coolant Hose Replacement
 
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Pelican Technical Article:

Porsche 911 Carrera Coolant Hose Replacement

Time:

1 hour1 hr

Tab:

$20 to $400

Talent:

***

Tools:

Knife, handheld hex tool set, pliers

Applicable Models:

Porsche 996 Carrera models (1999-05)
Porsche 996 Turbo, GT2, GT3 (2001-05)
Porsche 997 Carrera models (2005-12)
Porsche 997 Turbo, GT2, GT3 (2007-13)

Parts Required:

Water hoses, coolant

Hot Tip:

Use the better-quality German squeeze clamps

Performance Gain:

Prevent catastrophic hose breakdown

Complementary Modification:

Replace radiator, bleed coolant system

I've owned a lot of cars over the past several years, and the 911 Carrera by far has the most radiator hoses of all of them. When Porsche designed this car, they really didn't try to reduce the amount of rubber used in the assembly. As a result, the task of replacing all of the radiator hoses on the car is a really big chore. One of the more difficult parts is actually figuring out where they are all located! For that purpose, I've created a table of hoses and general locations to help you check your hoses and replace them if necessary. Please keep in mind that slight variations in hoses and locations have occurred over the length of production of the Carrera.

I recommend inspecting your rubber hoses every two years or so. As they age, they have a tendency to get hard and brittle. When you gently squeeze a hose, it should be relatively soft and easy to indent with your hand. It shouldn't feel like it is brittle or crunching when you squeeze it. It should spring back to its original shape pretty quickly after being compressed. If it feels very hard, then it might be time to replace it. If there is a bulge in the hose, or any type of crack in the surface of the hose, then you should replace it as well. Also check for wetness or leaks around where the hoses create their connections, that is a sign that the hose should be replaced. Some hoses may be coated with some leftover cosmoline from the factory. Don't mistake these for bad radiator hoses.

Unfortunately, there's no exact milestone on when to replace your radiator hoses. The recommended automotive industry standard is about four years or 60,000-80,000 miles. On some cars, they may last 10 years or longer depending upon how the car is driven or how it's stored during winter or summer months. Since there are so many hoses on the 911 Carrera, I suspect that many of these cars will have many of their original hoses still installed many years down the line.

Top Radiator Hoses: left and right (green).
Figure 1

Front Hoses 996 (connected to radiators) Bottom Radiator Hoses: left and right (blue arrow) Top Radiator Hoses: left and right (green). Radiator Vent Hoses: left and right (purple arrows) Intermediate Hoses 996 (connected to metal pipes in front wheelwells) Upper Hoses: left and right (yellow arrow) Lower Hoses: left and right (red arrow) Vent Hoses: left and right (purple arrow)

Rear Hoses 996 Coolant line to upper right side o
Figure 2

Rear Hoses 996 Coolant line to upper right side of engine (blue arrow) Coolant line from water pump (green arrow) Radiator vent hose (purple arrow) Heater core hoses (red arrow)

Center Third Radiator Hoses 996
Figure 3

Center Third Radiator Hoses 996 Left side A Right Side C 997 Hoses

Front Hoses 997 (connected to radiators) From wate
Figure 4

Front Hoses 997 (connected to radiators) From water pump (red arrow) To engine block (blue arrow) Vent line (yellow arrow) Cross over hoses (insert, green arrows) Hoses from front radiators to center radiator (optional not shown)

Under Body Hoses 997 (connected to metal pip
Figure 5

Under Body Hoses 997 (connected to metal pipes) From water pump (red arrows) To upper engine block (blue arrows) Heater core hoses (yellow arrows) Vent lines (hidden above, green arrow) Common Hoses 996/997

Coolant Tank Hoses 996/997 Lower hose con
Figure 6

Coolant Tank Hoses 996/997 Lower hose connections to coolant tank (red arrow) Upper coolant tank hoses (green arrows) Coolant tank overflow hose (purple arrow)

Engine Hoses 996/997 Thermostat hose (blue arrow) To splitter hose (gr
Figure 7

Engine Hoses 996/997 Thermostat hose (blue arrow) To splitter hose (green arrow) Return to engine hose (yellow arrow) Heater hose (red arrow)

Use some pliers or channel locks to release the clamp and slide it down the hose (orange arrow).
Figure 8

Use some pliers or channel locks to release the clamp and slide it down the hose (orange arrow). Then, use a razor knife to cut a slit in the hose along the length of the hose (green arrow). This will allow you to peel back the hose and easily remove it from the metal pipe.

The standard hose clamps used on the car when new are difficult to attach properly (orange arrow).
Figure 9

The standard hose clamps used on the car when new are difficult to attach properly (orange arrow). The nice advantage to these clamps is that they supply constant pressure around the hose even when it expands or contracts. For ease of installation, I often use German OEM screw-type hose clamps that will not loosen up or fail over time (green arrow).

Porsche redesigned some of the hose connections for the 997, and changed them to â€Ã...Â
Figure 10

Porsche redesigned some of the hose connections for the 997, and changed them to "quick disconnect". On these type of connections you simply pull out (but not completely off) the metal clip on the joiner (blue arrows) then pull the old hose off. Clean out the connection, push the wire clip back in, insert the new hose with the quick connector and push until you hear it snap in place.

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Comments and Suggestions:
Richardjjs Comments: I have a leak of coolant from the "top of the Engine" that drops down from the Right hand side of the front of the engine
On a run of about 80 miles it lost less than a 1/2 litre 1 pint
Tried to get it to do it once it had been raised but did not happen again
After a run over to our POrsche Garage 30 miles away 40 minutes driving the found a leak from "The top of the engine" can mentioned the Oil Cooler

Are there any pipes here please
May 3, 2016
  Followup from the Pelican Staff: The heat exchanger may be what is leaking. There are hoses attached to it, they can also leak.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
zenithblueC2 Comments: Hello Pelican, I need to replace this hose on my '99 C2.
Pelican Part No.: 996-106-850-05-M100 please see attached photo. It's the hose that connects directly to my water pump.

I'm not seeing a specific directions guide on your site to replace it unless I'm not looking in the correct spot.

If you have a tuitorial on how to replace said hose, please point me in the right direction.

Thank you very much.
May 2, 2016
  Followup from the Pelican Staff: Look for the Pelican water pump article, it may help you.

We don't currently have that tech article. If we get a chance to perform the procedure, we will be sure to document it.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Mario Comments: I'm looking for this hose for my 2000 Porsche 996 c4

March 18, 2016
  Followup from the Pelican Staff: That hose is part of the larger coolant hose next to it. I’m not the best with part numbers.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Ray Comments: The vertical green arrow in figure 6 in my car has a hole about 1 foot into the hose. Do I need to remove the engine to reach the far side of the hose? And what is it attached to?

Thanks
Ray
February 28, 2016
  Followup from the Pelican Staff: The hose goes to the either the engine vent (rear of engine) or radiator vent. Radiator vent is at bottom of vehicle, engine vent accessible from back of engine, remove intake.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
FS911 Comments: Hi there my name is frank just wondering if you guys would be able to tell me which hose I need..... I have coolant leaking from the front LHS just in front of the wheel, the coolant is coming from the underside of the bumper any help would be greatly appreciated thanks FRANK 😀
February 21, 2016
  Followup from the Pelican Staff: Probably a radiator hose or a radiator. Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
declandio Comments: Hi... in figure 6, RE the overflow hose pointed to by the purple arrow- where is the hose supposed to terminate?
February 6, 2016
  Followup from the Pelican Staff: I recall it just going down and being a drain in case the coolant overflows. It attaches to a heat shield (maybe). Been a while. - Nick at Pelican Parts  
tsagarilc2003 Comments: Do you have a help guide for the job?
January 18, 2015
  Followup from the Pelican Staff: I don't think so. All of the articles are located here: http://www.pelicanparts.com/techarticles/996_tech.htm #engine




We don't currently have that tech article. If we get a chance to perform the procedure, we will be sure to document it.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
tsagarilC2003 Comments: Hi, How do i access the hose that goes into the top of the OIL cooler Heat Exchanger? I have been told the engine needs to be dropped though there must be an easier way.
What about taking off the Manifold and airbag and compressor?
January 17, 2015
  Followup from the Pelican Staff: Remove the intake manifold. - Nick at Pelican Parts  
Abe Comments: What hoses do I need for 2004 Carrera 996 C2 3.6L. P/Ns please.

Is Swepco 201 is the best fluid to use for my 2004 C2 Carrera manual 6 speed.? If not what is the best fluid to use for hot weather. Do I use the same oil to change the transmission and differential fluids. and how much do I need.

Do you ship UPS to Saudi Arabia, and do you ship oil thru UPS International.
April 29, 2014
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
 

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