986 Forum - The Community for Porsche Boxster & Cayman Owners - View Single Post - Coolant leak

MNBoxster · 02-07-2007, 10:00 PM

@ Jinster,

Hi, pretty straightforward removal/installation. A couple things to consider though, you need to remove the Serpentine belt, it may be wise to replace it now. Also, you need to drain the cooling system, so new Coolant and maybe even a 'T'stat is a good idea. Also, be aware that you'll need to cut the gasket as it is shared with the Oil Pump which you won't remove, so be sure to have a drywall knife or razor blade.

One tip - with an Alloy Engine, you need to be very careful when scraping off old gasket material that you don't scratch or gouge the mating surfaces, or you may risk leaks. One trick I discovered serendipitously while doing a valve job on my Esprit - we mislaid the gasket scraper and rather than stop the project to look for it or go buy another, I had a polystyrene light switch plate (available for under $1 from any Lowes, Menards, etc.). I snapped it in two and it worked great. It has a sharp edge and being softer than the aluminum, you could really reef on it with no fear of scratching or marring the mating surface. It worked so well, that it's now the preferred tool in our Lotus Club for removing gasket material. If it dulls, you just snap it again to have a fresh sharp edge. I now always have several in my tool chest.

Another tip is to use a thin coat of Hylomar on the gasket (both sides) to insure a leak-proof seal. Hylomar is an anaerobic sealant which never truly hardens, so it seals any irregularities in the mating surface. It was invented by Rolls-Royce and is much better than any of the RTV Silicone sealants because unlike Hylomar, these RTVs will harden and not continuously seal through repeated expansion/contraction of heat cycling, eventually developing leaks. If you PM me with your email addy, I can send you the Coolant Pump replacement procedure step-by-step as a Word document. Hope this helps...

Happy Motoring!... Jim'99

02-07-2007, 10:00 PM	#7
MNBoxster Registered User Join Date: Sep 2005 Location: Minneapolis/St. Paul, Minnesota, USA Posts: 3,308	@ Jinster, Hi, pretty straightforward removal/installation. A couple things to consider though, you need to remove the Serpentine belt, it may be wise to replace it now. Also, you need to drain the cooling system, so new Coolant and maybe even a 'T'stat is a good idea. Also, be aware that you'll need to cut the gasket as it is shared with the Oil Pump which you won't remove, so be sure to have a drywall knife or razor blade. One tip - with an Alloy Engine, you need to be very careful when scraping off old gasket material that you don't scratch or gouge the mating surfaces, or you may risk leaks. One trick I discovered serendipitously while doing a valve job on my Esprit - we mislaid the gasket scraper and rather than stop the project to look for it or go buy another, I had a polystyrene light switch plate (available for under $1 from any Lowes, Menards, etc.). I snapped it in two and it worked great. It has a sharp edge and being softer than the aluminum, you could really reef on it with no fear of scratching or marring the mating surface. It worked so well, that it's now the preferred tool in our Lotus Club for removing gasket material. If it dulls, you just snap it again to have a fresh sharp edge. I now always have several in my tool chest. Another tip is to use a thin coat of Hylomar on the gasket (both sides) to insure a leak-proof seal. Hylomar is an anaerobic sealant which never truly hardens, so it seals any irregularities in the mating surface. It was invented by Rolls-Royce and is much better than any of the RTV Silicone sealants because unlike Hylomar, these RTVs will harden and not continuously seal through repeated expansion/contraction of heat cycling, eventually developing leaks. If you PM me with your email addy, I can send you the Coolant Pump replacement procedure step-by-step as a Word document. Hope this helps... Happy Motoring!... Jim'99 Last edited by MNBoxster; 02-07-2007 at 10:03 PM.