Porsche Parts Catalog Porsche Accessories Catalog Porsche Technical Articles Porsche Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
Coolant Expansion Tank Replacement
 
Bookmark and Share

Pelican Technical Article:

Coolant Expansion Tank Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$360

Talent:

**

Tools:

10mm socket, flathead screwdriver

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

New expansion tank, coolant

Hot Tip:

Replace the tank with the engine cold

Performance Gain:

A major cooling system leak fixed

Complementary Modification:

Flush cooling system

Over time, the coolant expansion tank tends to turn yellow, become brittle and form micro fractures and sometimes leak. When the car warms up, both the heat and pressure of the coolant starts to attack the weakest point of the tank, eventually causing it to fail and the car starts leaking coolant. The good news is that the replacement tank is relatively inexpensive and can be changed in less than an hour.

Take a look around the coolant tank. In some instances, you can instantly see it has been leaking. In others, you may only see a faint trace of coolant weeping/staining the crack or seam. It's important to tackle this problem as soon as possible.

You do not need to drain all the coolant from the vehicle. Just drain enough so that it is below the coolant reservoir. If the coolant in the car is new, there is no reason to replace it as long as you drain it into a clean container. Coolant is expensive and not too great for the environment. So if the coolant in your car is good, try and save it to reuse. If your coolant is old, this is also a good time to perform a flush and install new coolant. Please see our article on coolant flush for additional assistance.

The coolant expansion tank on the 944 and 951 is different. There are extra ports on the turbo tank. For some reason, they are a lot more expensive than a regular 944 tank, so make sure you are ordering the right tank for your car.

If you are just replacing the coolant expansion tank, use a turkey baster or fluid pump to remove the coolant from the tank.
Figure 1

If you are just replacing the coolant expansion tank, use a turkey baster or fluid pump to remove the coolant from the tank. There may still be a little spillage when you remove the lower hose so be prepared for it. Open the reservoir (red arrow) and either suck as much fluid as you can out from the top or place a container under the lowest hose (green arrow) and remove that hose and drain the coolant into the container. If you are draining the fluid out from the bottom hose, you will need to remove the intake tube first.

Use a flathead screwdriver and remove the two screws (red arrows) and the cold air intake tube to the air box.
Figure 2

Use a flathead screwdriver and remove the two screws (red arrows) and the cold air intake tube to the air box.

With the screws removed pull the tube out from the forward fender area (red arrow) and remove it.
Figure 3

With the screws removed pull the tube out from the forward fender area (red arrow) and remove it.

While you may be able to disconnect and remove everything attached to the coolant expansion tank with the intake manifold tube attached, I find it much easier to use a flathead screwdriver and loosen all the hoses attached to the tube (red arrows).
Figure 4

While you may be able to disconnect and remove everything attached to the coolant expansion tank with the intake manifold tube attached, I find it much easier to use a flathead screwdriver and loosen all the hoses attached to the tube (red arrows). Separate the hoses attached to the tube and remove the tube from the vehicle.

With the tube removed, you have much easier access to the expansion tank hoses.
Figure 5

With the tube removed, you have much easier access to the expansion tank hoses. Use a flathead screwdriver and remove the three clamps and then the hoses attached to the tank (red arrows).

Disconnect the overflow hose from the neck of the tank.
Figure 6

Disconnect the overflow hose from the neck of the tank. There is a hole in the tank that this hose passes through, so be aware of it when installing the new tank.

With all of the hoses disconnected, you have easier access to the single 10mm nut on the side of the tank.
Figure 7

With all of the hoses disconnected, you have easier access to the single 10mm nut on the side of the tank. Use a 10mm socket and remove the nut (red arrow).

The expansion tank is held in place by two of the fender bolts.
Figure 8

The expansion tank is held in place by two of the fender bolts. Use a 10mm socket and remove the two bolts

You can now remove the tank from the vehicle.
Figure 9

You can now remove the tank from the vehicle. Installation is the reverse of removal. Check all hoses and clamps while working and replace them as needed. Remember to check for leaks when finished.


Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Wed 12/7/2016 02:49:27 AM