Note to moderators - can you move this to 996FAQ?
Ok, as promised I have put together instructions to enable DiY on certain common faults. To start with C2 / C4 3.4 header tank remove and refit, I really do hope this helps a few out as it has taken a lot of time and effort.
These instructions will also be the same for 3.6 models except you will need to remove the obstructing air pump first.
Tools required:
A pair of mole-grips
17mm open end spanner
19mm open end spanner
Flat ended screwdriver
10mm deep socket
Long nose plyers (pref. with 45deg bend like in photo)
Also need some rag - or steal one of the other halves favourite tops!
Enough antifreeze to top up or do a complete change.
Out of preference I am using 4 litres of Red long-life concentrate.
(Testing the strength afterwards this has given me upto minus 29deg which is fine) This is made by Comma & is Porsche approved
Ok, lets go... open the engine cover
Remove the air trunking, simply twist, push pull, you will get the jist, it eventually pops out. If not you will notice push down clips, apply pressure to those using the flat ended screwdriver.
Set the mole grips to a gap of say 10mm ish
Now clamp the mole grip onto the top hose clip, slide the clip down the hose to enable pulling the hose off, do the same with the lower one.
The hose that comes in from the rear at the top of the tank is difficult to get at so this is where 45deg angle long nose plyers come in
Undo the 10mm nut
Use 19mm spanner to crack the front brass fuel union. Don't panic, you get hardly any fuel come out, just a tiny spray when right at the top of the thread. Detach from rail and tuck to one side
Now use 17mm spanner to do the same on the union just next to it
Under the tank you will see a 2" bore alloy water tube held to the chassis by a C-clip. Simply pull out of the clip
Push it down and out the way as much as possible, the more the better but you'll find it will only drop by about 1"
Start to wriggle the tank towards the engine by about 1 - 2", once it has come that far it will then push downwards and out of the Black retaining bracket
Now you can unclip the hose out of the top of the tank
Ok, almost ready to pull out. Now just look at the situation, tie back / tuck away all hoses and pipes that are in the way around the tank, the more room you can make the better, the tank is wedged in there.
Now start to manipulate as gently as you can the tank to come out, take your time and ** BEWARE - there is a level sensor in the base of the tank, they are VERY BRITTLE so do not force the tank and snap this off.
Once you have got half way out reach underneath and disconnect the loom using the flat ended screwdriver on the locking clip.
Once out you can easily remove the sensor, looking straight at the sensor just twist anti-clockwise it then comes out
Use the flat end screwdriver to pry off the overspill hose
Make sure the receiving area is something like this (all pipes tucked away & the 2" alloy pipe pushed down)
Next step has 2 options
OPT. 1 = Fit overspill hose to new bottle and the level sensor then gently manipulate tank back into place (BEWARE - of the sensor again, don't force it, they break easy)
You can clip the loom on at this stage or when it is in place
OPT 2 = Fit the overspill pipe but wait until tank is mounted on bracket and insert the sensor last, although tricky this is in my opinion the easier and safer way, REMEMBER TO LOCATE THE HOSE INTO CLIP before you attach the tank to the bracket otherwise you will not have room
Nearly there, attach all the hoses back on, reconnect fuel lines, clip loom to level sensor if you haven't already and then pour in the antifreeze. Then use as much water as needed to bring to level
With tank cap off start engine and leave ticking over, the level may drop a few inches just keep topping it back up to level. After about 2 - 4 minutes it will stable then fit cap but put purge clip in up-right position
Take car on a short run then check level, top up if required, attend to leaks if needed. Leave the purge clip up for a few drive cycles to get as much air out of the system as possible.
Ok, as promised I have put together instructions to enable DiY on certain common faults. To start with C2 / C4 3.4 header tank remove and refit, I really do hope this helps a few out as it has taken a lot of time and effort.
These instructions will also be the same for 3.6 models except you will need to remove the obstructing air pump first.
Tools required:
A pair of mole-grips
17mm open end spanner
19mm open end spanner
Flat ended screwdriver
10mm deep socket
Long nose plyers (pref. with 45deg bend like in photo)
Also need some rag - or steal one of the other halves favourite tops!
Enough antifreeze to top up or do a complete change.
Out of preference I am using 4 litres of Red long-life concentrate.
(Testing the strength afterwards this has given me upto minus 29deg which is fine) This is made by Comma & is Porsche approved
Ok, lets go... open the engine cover
Remove the air trunking, simply twist, push pull, you will get the jist, it eventually pops out. If not you will notice push down clips, apply pressure to those using the flat ended screwdriver.
Set the mole grips to a gap of say 10mm ish
Now clamp the mole grip onto the top hose clip, slide the clip down the hose to enable pulling the hose off, do the same with the lower one.
The hose that comes in from the rear at the top of the tank is difficult to get at so this is where 45deg angle long nose plyers come in
Undo the 10mm nut
Use 19mm spanner to crack the front brass fuel union. Don't panic, you get hardly any fuel come out, just a tiny spray when right at the top of the thread. Detach from rail and tuck to one side
Now use 17mm spanner to do the same on the union just next to it
Under the tank you will see a 2" bore alloy water tube held to the chassis by a C-clip. Simply pull out of the clip
Push it down and out the way as much as possible, the more the better but you'll find it will only drop by about 1"
Start to wriggle the tank towards the engine by about 1 - 2", once it has come that far it will then push downwards and out of the Black retaining bracket
Now you can unclip the hose out of the top of the tank
Ok, almost ready to pull out. Now just look at the situation, tie back / tuck away all hoses and pipes that are in the way around the tank, the more room you can make the better, the tank is wedged in there.
Now start to manipulate as gently as you can the tank to come out, take your time and ** BEWARE - there is a level sensor in the base of the tank, they are VERY BRITTLE so do not force the tank and snap this off.
Once you have got half way out reach underneath and disconnect the loom using the flat ended screwdriver on the locking clip.
Once out you can easily remove the sensor, looking straight at the sensor just twist anti-clockwise it then comes out
Use the flat end screwdriver to pry off the overspill hose
Make sure the receiving area is something like this (all pipes tucked away & the 2" alloy pipe pushed down)
Next step has 2 options
OPT. 1 = Fit overspill hose to new bottle and the level sensor then gently manipulate tank back into place (BEWARE - of the sensor again, don't force it, they break easy)
You can clip the loom on at this stage or when it is in place
OPT 2 = Fit the overspill pipe but wait until tank is mounted on bracket and insert the sensor last, although tricky this is in my opinion the easier and safer way, REMEMBER TO LOCATE THE HOSE INTO CLIP before you attach the tank to the bracket otherwise you will not have room
Nearly there, attach all the hoses back on, reconnect fuel lines, clip loom to level sensor if you haven't already and then pour in the antifreeze. Then use as much water as needed to bring to level
With tank cap off start engine and leave ticking over, the level may drop a few inches just keep topping it back up to level. After about 2 - 4 minutes it will stable then fit cap but put purge clip in up-right position
Take car on a short run then check level, top up if required, attend to leaks if needed. Leave the purge clip up for a few drive cycles to get as much air out of the system as possible.