Installing coolant pump

No. Procedure

8 Rework new spare metal seal

Fasten coolant pump

9 Fit drive belt and tension

Install rear-wall lining, service cover and left-hand seat instruction

Undo hexagon-head bolts. The lower right hexagon-head bolt is difficult to reach. To undo it, use flexible-head socket wrench 4001-10 by Stahlwille.

Cut old metal seal between coolant pump and water guide housing at the connecting webs.

Instruction

Cut new spare metal seal (combination seal) for coolant pump and water guide housing at the connecting webs.

Fit new sea! and coolant pump simultaneously and fasten. Tightening torque 10 Nm (7 ftlb.}.

Fit drive belt by hand, slightly pre-tensioned, in the following sequence:

First onto the coolant-pump drive pulley (1), alternator drive pulley (2), intermediate roller (3), power-steering pump drive pulley (4), air-conditioning compressor drive pulley (5), crankshaft pulley (6), idler roller (7), then over the tensioning roller (8). To do this, turn the tensioning roller (wrench size 19 mm) clockwise, hold still and put on the belt at the same time. Slowly relieve the tensioning roller. Check that the belt is correctly seated on all drive pulleys.

Insert rear-wall lining in lower area behind the heel-plate lining.

Fasten service cover with 9 hexagon-head bolts. Tightening torque 10 Nm (7 ftlb.) Connect electrical plug connection and fasten seat. Tightening torque of Torx screws 20 Nm (15 ftlb.).

19 5S 19 Removing and instiling coolant regulator

Tools

Tools

986 Engine Timing Porsche Procedure

302.S7

Item Designation

Assembly aid

Special tool

9627

302.S7

Explanation

Removing and itts£a£Ejng ecoiani regulator

986 Engine Timing Porsche Procedure

393-96 g

19 58 19 Removing and installing cooiant regulator 986191 Printed in Germany - 12, 1997

Removing and installing coolant regulator

No. Procedure

Instruction

Remove rear underside panel

Undo spring-band clamps

Clamp shut coolant hoses and undo spring-band clamp with pliers.

Drain coolant

Undo drain plug at water guide housing and collect coolant. Undo four hexagon-head bolts and remove housing with coolant regulator. Replace gasket for drain plug. Tightening torque 10 + 5 Nm (7.5 + 3.5 ftlb.}

3+4 Remove or install coolant regulator Press special tool assembly aid 9627 down against the spring force and simultaneously turn coolant regulator out of the housing guide or into the housing guide in the case of installation.

Install housing with coolant regulator Replace housing seal and install housing with assembled coolant regulator. Tightening torque 10 Nm (7.5 ftlb.).

19 73 19 Removing and installing coolant temperature sensor

The place of installation is at the left front in the direction of travel, in the area of cylinder 4.

Removal

1. Remove rear underside panel.

2. Pul! off electrical plug connection. Undo temperature sensor (wrench size 22).

Installation

1. Check sealing ring and use a KD (service) sealing ring if necessary.

Note

As standard, the temperature sensor has a captive sealing ring.

Eclipse Coolant Sensor Housing
442- 96

IS 33 17 Raising and filling in ccoiant (includes: bleeding the cooEing system)

Drain coolant

1. Remove cap from coolant expansion tank.

2. Undo drain plug on water guide housing.

Eclipse Coolant Sensor Housing
471-96

3. Disconnect vent line.

I / /

—it

r~

467-95

13 38 17 Draining and filling in coolant (includes: bleeding the cooling system) 19 - 13 Printed in Germany - 12, 1997 9861913

FilEing in cooiant and bleeding

Note

The engine cooling system is factory-filled with a lifetime engine coolant. This engine coolant must not be mixed or replaced with other coolants. Use only original Porsche coolant when changing or topping up the engine cooiant.

1. Remove both caps (engine oil and coolant).

2. Lever cover off with a spatula.

Picture Porsche 986 Engine
406-96

3. Lift bow on bleeder valve. Screw oil cap on again.

Porsche 986 Tiptronic
407-96

4. On Tiptrorcic vehicles, the pneumatically triggered coolant shutoff valve (flat-seat valve) must be opened for the bleeding process. The electric switch-over valve must be switched off for this purpose.

Porsche 924

97-335

Triggering can be performed with the Porsche System Tester 2 or by pulling out the Tiptronic control module fuse B1 with the ignition switched off.

6. Put on protective cover. {Manufacturer: refer to Workshop Equipment Manual.)

Fuse B1 (arrow)

97-335

5, Check whether the coolant shutoff valve is open.

7. Fill with coolant up to the bottom edge of the filler neck.

Lower Control 986

97-277

S. Run the engine at idle speed and top up with coolant until no more coolant flows into the cooiing system when the engine is revved moderately. (Coolant level now at lies lower edge of filler neck.) The cooilant temperature must not exceed 80 °C; proceed directly to the next work step if necessary.

9. Close reservoir and warm engine up to operating temperature at a speed of ~ 2500 rpm until the thermostat opens after approx. 10 minutes (coolant temperature ~ 90 DC).

Check: The radiator supply lines and return lines in the front wheel housings must be hot.

97-277

10. Allow engine to run an additional 5 minutes at - 2500 rpm. Every 30 seconds, briefly rev up the engine to - 5000 rpm. Rpm surges are important for proper bleeding.

Note

The level warning light can light up during the bleeding process (reset by restarting the engine). Interrupt the procedure if the coolant level is below the "MIN" mark. Open reservoir with extreme caution and allow overpressure to escape until the coolant level reaches the lower edge of the filler neck; top up with coolant if necessary. Again intermittently rev the engine for 5 minutes,

11. Allow engine to run at idle speed until any activated radiator fans switch off again. Then switch off the engine. Open reservoir cap with extreme caution until the reservoir is depressurised (danger of scalding!).

12. Top up coolant expansion tank until level reaches lower edge of filler neck (cold, this corresponds to = "MAX").

13. Reposition bow on bleeder shutoff valve. Unscrew oil cap.

14. Put on cover and body seal. Screw on both caps. Remove protective cover.

15. Reactivate ATF shut-off valve on Tiptronic vehicles.

19 01 01 Checking cooling system for leaks

Porsche 944 Extreem
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