Go Back   986 Forum - for Porsche Boxster & Cayman Owners > Porsche Boxster & Cayman Forums > DIY Project Guides

Reply
 
LinkBack Thread Tools Display Modes
Old 03-22-2015, 05:12 PM   #1
Registered User
 
truegearhead's Avatar
 
Join Date: Jul 2011
Location: Richmond, VA (The Fan)
Posts: 683
Easy way to change the expansion tank

I tackled the expansion tank replacement this afternoon, and was able to knock it out in about 45 minutes(far from the Pelican 4 hour estimate). I found that if you cut part number 15(see image below) in half you only need to remove one hose in the engine bay which you can remove from the engine bay (so nothing needs to be done under the car).


Stu

__________________
1997 2.5 Boxster NASA Time Trial track car
2003 911 C2
NASA HPDE Instructor
truegearhead is offline   Reply With Quote
Old 03-22-2015, 06:35 PM   #2
Registered User
 
Join Date: Jan 2015
Location: Moore, Ok
Posts: 105
Garage
What did you use to cut it?
Redboxs is offline   Reply With Quote
Old 03-24-2015, 09:44 AM   #3
Registered User
 
Join Date: Mar 2004
Location: Belgium
Posts: 9
Garage
Expansion tank replacement.

1.Same question as put by REDBOXS and could you add a drawing of the cutting pattern ?
2. Did you re-use this part or did install a new one ?

Tx

Alfred
privateselling is offline   Reply With Quote
Old 03-27-2015, 02:50 AM   #4
Beginner
 
Jamesp's Avatar
 
Join Date: Mar 2013
Location: Houston
Posts: 1,659
Garage
I'm all ears.
__________________
2003 S manual
Jamesp is offline   Reply With Quote
Old 03-27-2015, 04:54 AM   #5
Registered User
 
Join Date: Feb 2005
Location: It's a kind of magic.....
Posts: 5,082
One concern I would have with this procedure would be how to prevent the plastic debris from the cutting process from getting into the cooling system. Such material would have the same basic effect as water pump impeller bits if circulated in the cooling system.
__________________
Anything really new is invented only in one’s youth. Later, one becomes more experienced, more famous – and more stupid.” - Albert Einstein
JFP in PA is offline   Reply With Quote
Old 03-30-2015, 08:46 PM   #6
Senior Member
 
Join Date: Feb 2013
Location: So Cal
Posts: 67
I want to hear how you did this

I did mine and it took about 3 hours with a friend.
Be careful not to crack the oil fill tube on the engine compartment side. I cracked mine as it got hard and brittle from years of heat exposure. Im not talking about the flex hose Im talking about the the part that the flex hose connects to.

Last edited by Specwar; 03-31-2015 at 05:29 PM. Reason: spelling and additions
Specwar is offline   Reply With Quote
Old 04-22-2015, 09:54 AM   #7
Registered User
 
Join Date: Sep 2008
Location: north east
Posts: 8
I need to do mine..... A few questions I've looked at lots of photos of the bottle from all angles, can someone explain why the entire assembly doesn't simply slide/lift into the boot side of the bulkhead with the plastic manifold (when all the bolts are removed)?? with all the hoses still connected, why would I need to unclip the hoses on the engine side when there are clips & separate hoses on the boot side and it looks like the oil filler hose detaches from the underside of the bottle.
stevensred5 is offline   Reply With Quote
Old 04-23-2015, 07:09 AM   #8
Registered User
 
Join Date: Jan 2007
Location: BC
Posts: 1,259
It's too tight on the engine side to pull into the rear trunk, at least with the hose on the passenger side still connected. Once that one's loose, you can do it, with some effort.

With respect to the OP's method of cutting the part, somehow that doesn't sit right with me. Esp. when there's a way to do it without having to butcher parts that stay in the car.

For example, My DIY:

Another coolant tank replacement DIY
__________________
2001 Boxster, 5 spd, Seal Grey
clickman is offline   Reply With Quote
Old 08-15-2015, 07:40 AM   #9
1997 Boxster - 56K miles
 
Join Date: Apr 2012
Location: Texas
Posts: 8
Just completed the coolant tank replacement for a 97 Boxster with 58,000 miles. I did a similar process as Truegearhead, except I was able to pull the hoses out into the trunk just enough to reach the clamps with a 45 degree needle nose plier. It would have helped to have an assistant push on the hoses from inside the trunk area. Then I removed the hoses going from the manifold to the tank and cut out the connectors from the plastic manifold (see pics). I used a small hacksaw and an X-ACTO craft saw (pic) to cut the plastic, then sanded down the sharp edges. I did not use or need the cable clamp pliers. Even with the connectors cut, it was still a PITA to attach to hoses coming from engine area - need to pull on hose, insert connector and tighten screw clamp. I used screw type clamps to reattach the hoses to both sides of the connectors. Then I cut the rubber gasket so it would fit around the hoses. Although probably not necessary, I taped the gasket to the body and covered the opening with duct tape.

ronlatta is offline   Reply With Quote
Old 08-15-2015, 10:41 AM   #10
On the slippery slope
 
JayG's Avatar
 
Join Date: Mar 2014
Location: San Diego
Posts: 3,271
Garage
Quote:
Originally Posted by Jamesp View Post
I'm all ears.
That's what Ross Perot said
__________________
2004 Boxster S 6 speed - DRL relay hack, Polaris AutoTop DIY
2004 996 Targa Tip
Instructor - San Diego region, 2014 Porsche Performance Driving School
2013 C300, 2010 Jetta 2011 Mazda 3, 1998 Windstar - Dog van , 2004 F-150 "Big Red"
JayG is offline   Reply With Quote
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -8. The time now is 08:22 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
Copyright 2018 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page