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Porsche 911 Carrera Radiator and Fan Replacement
 
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Pelican Technical Article:

Porsche 911 Carrera Radiator and Fan Replacement

Time:

4 hours4 hrs

Tab:

$180

Talent:

***

Tools:

Torx driver set

Applicable Models:

Porsche 996 Carrera (1999-05)
Porsche 997 Carrera (2005-12)

Parts Required:

Radiator, fan, hoses, coolant

Hot Tip:

Install the center radiator for improved cooling

Performance Gain:

Cooler-running engine

Complementary Modification:

Replace hoses, repaint front bumper

Proper maintenance of your coolant will go a long way toward extending the life of your radiator. The cooling systems on most cars are often very neglected, as most owners don't know much about them (see Project 29 for more information). The most vulnerable components in the entire system are the radiator and the heater core, as they tend to be damaged by corrosion and electrolysis. Poor maintenance of the system can result in the buildup of corrosion elements in both the radiator and heater core, creating clogs and leaks that decrease cooling performance. If the engine overheats, the additional heat from the coolant can also damage sensitive plastic attachments and components.

When replacing your radiator, you want to make sure that you replace it with one that meets or exceeds the OEM cooling standards. Although Porsche cooling systems don't typically fail very often, age and neglect may lead to overheating problems. Therefore, it may be a wise idea to install a center-mounted radiator that performs a better job of cooling than the standard pair (see Pelican Technical Article: Installing a Center Radiator on the Porsche 911 Carrera). I also recommend replacing your water pump, radiator hoses, thermostat, and any hose clamps too (PelicanParts.com sells complete kits for this replacement). All of these components can be damaged by a cooling system that has overheated. It's also a good time to swap out your old belt.

The first step in replacing your radiator is to remove all of the coolant from the system (see Pelican Technical Article: Porsche 911 Carrera Coolant Flush). Now, you need to gain access to the radiator. Remove the front bumper cover and pull back the front part of the inner wheelwell liners (see Pelican Technical Article: Front Bumper Wheel Liner Replacement on the Porsche 911 Carrera). It is possible to remove the radiators without removing the front bumper cover, but it takes only a few minutes to remove it and it makes the job a whole lot easier in my opinion. Follow the removal procedure detailed in the photos to remove the radiator/fan assembly.

The installation is basically the reverse of removal. Use new clamps on your new radiator hoses. Top off and bleed your coolant system as detailed in Pelican Technical Article: Porsche 911 Carrera Coolant Flush. Keep an eye on the front of your car for coolant leaks for about a week after the installation and tighten up any hoses that show any signs of leakage or weeping.

It's a good idea to use these instructions to clean out the radiators every spring, as they tend to collect a lot of debris, which decreases their cooling efficiency over time. This can also lead to moisture collection and premature corrosion of the radiator.

It's also a good idea to check the proper operation of the radiator fans while you have access to them, as the resistor packs that help to power them tend to fail. You can turn on and test the fan speeds using the Porsche PST-2 tool, or you can simply turn on the air conditioning system, and that should trigger the high-speed level of the fans. If you start the car and let it warm up, it should start the fans in low speed mode before graduating to the higher speed mode.

With the front bumper removed (<a style=color:000080 href=https://www.
Figure 1

With the front bumper removed (Pelican Technical Article: Front Bumper Wheel Liner Replacement on the Porsche 911 Carrera), you should have easy access to both the right and left radiators. Begin by removing the large rubber air funnel that is located in front of each radiator--it is held on with five screws (lower left). Then, cut a slit in the lower radiator hose (996 only) and allow the coolant to empty out of the radiator and hoses (yellow arrow).

Detach the air conditioning condenser from the front by removing the two bolts (green arrows) and sliding it out of its mounting tab (red arrow).
Figure 2

Detach the air conditioning condenser from the front by removing the two bolts (green arrows) and sliding it out of its mounting tab (red arrow). Using a zip tie, secure the air conditioning condenser to the chassis. This is to assure that the condenser pipes do not become damaged while you're working on the radiator (upper left inset). The lower left inset photo shows the rubber air funnel for the right side of the car--the temperature sensor boot must be carefully threaded out of this boot upon removal.

On the 997 the air conditioning condenser is mounted to the front of the radiator buy one bolt on the outside (red arrow) and buy two clips that it sits in on the inside (blue arrows and insert upper right).
Figure 3

On the 997 the air conditioning condenser is mounted to the front of the radiator buy one bolt on the outside (red arrow) and buy two clips that it sits in on the inside (blue arrows and insert upper right). Remove the bolt and slip the condenser from the clips. The yellow arrow shows how debris can build up inside the air ducts. This radiator is from a one year old Southern California car. If you live in area that sees four seasons, you should check your ducts at least once a year. The lower left insert shows the Torq bolt that holds the fan shroud on to the back of the radiator (green arrow)

This photo shows the backside of the 996 radiator and fan assembly with the inner fender liners removed (see <a style=color:000080 href=https://www.
Figure 4

This photo shows the backside of the 996 radiator and fan assembly with the inner fender liners removed (see Pelican Technical Article: Front Bumper Wheel Liner Replacement on the Porsche 911 Carrera). In order to remove the radiator and fan assembly, you need to disconnect the small radiator vent hose (red arrow). I recommend replacing this hose during this procedure, so you might save some time and effort by just clipping it off. Unclip the vent hose from the radiator bracket (blue arrows). The green arrow shows the upper radiator hose. In a similar manner, I also recommend just cutting it, since you will be replacing it anyways. Sometimes it can be nearly impossible to remove the hose from the radiator, and you will need to cut it off to remove it (inset photo). If you decide not to remove the front bumper cover, then you will need to remove the fender brace (white arrow), and detach the headlamp vent hose as well.

This photo shows the back side of the 997 radiator and fan assembly with the inner fender liners removed (see <a style=color:000080 href=https://www.
Figure 5

This photo shows the back side of the 997 radiator and fan assembly with the inner fender liners removed (see Pelican Technical Article: Front Bumper Wheel Liner Replacement on the Porsche 911 Carrera). In order to remove the radiator and fan assembly you need to disconnect the radiator vent line (blue arrow). The 997s use quick disconnects on the radiator lines, even if you are going to be replacing the hoses do not cut the lines. The vent line is a simple push in pull out and the water hoses use the quick disconnect clips (yellow arrow). After disconnecting the hoses remove the Torx bolt (green arrow) that hold the fan shroud on and then the two smaller bolts that hold the radiator (red arrows). Move underneath the radiator and remove the two clips (inset, purple arrows).

The yellow arrow shows the electrical connection to the fan that must be disconnected.
Figure 6

The yellow arrow shows the electrical connection to the fan that must be disconnected. Pull out the resistor pack from its bracket and loosen the wire harness (green arrow). Disconnect the rear radiator air guide from the metal radiator bracket (red arrow). Finally, disconnect the bracket from the chassis by removing the nuts that hold it in place (blue arrow).

Here is a shot of the radiator area after the radiator has been removed.
Figure 7

Here is a shot of the radiator area after the radiator has been removed. The radiator-like unit on the left is the air conditioning condenser.

On the left is shown a brand new OEM 996 replacement radiator.
Figure 8

On the left is shown a brand new OEM 996 replacement radiator. If you are merely replacing the radiator fan and are reinstalling the old radiator, be sure to blow out the dirt and debris with some compressed air (right).

The radiator fan assembly is clipped to the rear of the radiator using metal snap clips (inset photo).
Figure 9

The radiator fan assembly is clipped to the rear of the radiator using metal snap clips (inset photo). Remove these snaps, and the fan assembly should lift right off. The fan is attached to the fan housing via three mounting screws located on the backside. A new fan is shown in the lower right.

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Comments and Suggestions:
Gilo Comments: Are the 997 center radiators different in size from the 996 center radiators that you sell as kits?
August 14, 2016
  Followup from the Pelican Staff: I believe so. To be sure, Give our parts specialists a call at 1-310-626-8765
- Nick at Pelican Parts
 
GEZ Comments: Can you replace 996 radiators with 997 radiators?
August 14, 2016
  Followup from the Pelican Staff: No, the fitting and radiator construction is different. - Nick at Pelican Parts  
Lucas Comments: What is the part number for the upper radiator hose? I have now ordered the wrong part twice. Do you take exchange or returns on ordering the wrong hose? Thanks
April 1, 2016
  Followup from the Pelican Staff: I am sure the Pelican Parts team can help you get the right hose and accept the return.
return policy:

http://www.pelicanparts.com/support/ReturnPolicy.htm

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
 
Errol Comments: I am about to replace my 2001/996 C2 radiators as i'm losing coolant which i identified by steam coming from my bonnet , coolant dripping from the drivers side wheel arch and on one occasion the low coolant level light flashing. I have just removed the bumper , rubber air funnel and disconnected the A/C condenser from its mount and zip tied it up. Now i can see one radiator is wet and obviously leaking i'll replace both rads as the bumper is off. My question is simply. .. Do i need to remove the radiator fan assembly to get the radiators out? I changed the condensers myself 4 years ago so they're ok
October 21, 2015
  Followup from the Pelican Staff: Yes, the cooling fan has to come out first. - Nick at Pelican Parts  
C4RTS Comments: On a C4S the bumper attachment holes points underneath are on brackets that attach to radiator. Can these brackets be replaced without draining cooling to remove radiator? I don't know how to get a response so feel free to email me...defi4554@mypacks.net
November 30, 2014
  Followup from the Pelican Staff: Good question, I am not sure. Our parts specialist may be able to tell this from a parts diagram. Give our parts specialists a call at 1-888-280-7799.
- Nick at Pelican Parts
 
Arlan Comments: My 1999 911 996 Cabriolet, 2 wheel drive, engine compartment fan came on when I turned the key on without starting the engine. Car had been sitting over night. It only did it that one time now it and all cooling fans do not come on at all ever even when hot when driving or not.
September 16, 2014
  Followup from the Pelican Staff: Could be an issue with the coolant temp sensor or the a/c was on. - Nick at Pelican Parts  

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