Coolant level sensor replacement

[Richard Bruce]

Has anyone of you folks ever replaced the coolant level sensor (in the bottom of coolant tank) without removing the tanks? Thx, i need to replace mine. this is an 02 base.

Thx for any feedback.

[Mark_T]

Not sure if it can be done, as I replaced mine when I replaced the tank. As these tanks are notorious for cracking at about the age yours is at, you might want to consider changing the tank, sensor, and cap all at the same time (if you don't already have the upgraded cap). Save yourself an unscheduled repair down the road.

If you do that, then you might also want to change out the water pump, thermostat, and coolant if they are still the original, possibly moving to a low temp thermostat while the opportunity is there.

And if you are going to do all that, then you should probably drop the front bumper and clean all the debris out from between the rads and condensers.

And thats how a $40 sensor turns into a thousand bucks and a weekend's work.

[Heiko]

Yes can be done easily... If careful you can do it without removing any hoses.. Just loosen the tank enough so you can get enough space to clear the sensor out the bottom. Pull the plug on the old sensor, turn it 45degrees and pull it out. Carefull not to break the new one when you guide it back into the opening.
H

[Richard Bruce]

Mark, Heiko thx for the reply. Regretfully I have replaced the tank w/o replacing the sensor. Shame on me. Thx guys.

[Richard Bruce]

Well, I replaced the coolant level sensor and the light continues to flash. I disconnected the sensor and the light goes out. I then removed the sensor and wrapped a cloth around it and the light remains out. Removed the cloth and the light comes back on.
Understanding the circuit, the switch is normally open and must be surrounded (in the tank) with fluid, for the switch to remain open. Once the fluid level drops, losing the density surrounding it the switch closes and turns the light on.

My tank is full so I don't have a clue why the light is coming on. any ideas?
Thx in advance for any suggestions.

BTW I tried my old switch with same result.

[Richard Bruce]

I found the float in the tank was being held on the bottom of the tank from a piece of plastic on an interior seam of the tank. This was excess from the plastic mold. Poor manufacture QC. A non Porsche tank I had replaced last month.

[Mark_T]

Good catch, especially considering how difficult it is to get at that area to see what's going on. Did you have to take the tank out to trim the plastic?

Don't you hate that? So much of your time and money wasted because some bean counter decided it wasn't worth the extra cost of trimming the plastic from the part before sending it out.

[Richard Bruce]

Fortunately I was able to reach the plastic piece with a pair of needle nose pliers. Yes after paying all that money for the tank, I would have expected better QC.

[clickman]

See my post here for an explanation of how that sensor works.

http://986forum.com/forums/performance-technical-chat/50904-how-coolant-tank-sensor-works.html#post388051