How hard can coolant tank replacement be?

[njbray]

Seems like I need a new coolant expansion tank. Was going to book it in as it was due for coolant change and installing my low temp thermostat - But Thinking of doing myself, just because!
Is it really the pain to do as some people say?
Any experiences, advice, cheats, etc welcome.
Also what other bits can I do while i'm at it?
Thanks.

[BoxsterSteve]

It’s a PITA DIY, four middle fingers out of five.
My tank was toast, so I cruised the DIY pages online. Pedro’s site shows how he did it all from up top.
I jacked the back of the car only on 18” stands, not only to gain underside access, but it kep the coolant lines to the tank from dribbling coolant into the trunk and saved me from burping the cooling system afterwards.
You’ll need that cable operated tool to remove the factory clamps, and pick up an oil fill tube too, because mine was really brittle and let go. Glad I had one ahead of time, saved me a trip to my Indie to pick one up part way through the job.
I removed the tank through the trunk, cutting it into pieces with a RotoZip tool and got all the hose connectors undo through the trunk too.
My hands are way too big, so I had to take the diamond shape brace from under the car and work from the bottom to hook all the tubes up again.
Certainly not a fun job, but definitely doable and I had a strong feeling of accomplishment afterward, probably because it was such a pain.

[kk2002s]

Patience, patience, patience
+1 PITA. Make sure no youngsters are within hearing distance
It's all in those hoses, oil fill on the engine side of the firewall
I worked under and on top to get them undone and connected. I did not cut the old apart
I had it stuffed and it now hangs on my fireplace mantle

Have to use cable clamp tool. I was worried about breaking the oil fill tube but fortunately it did not. They aren't to expensive, so it could be good time to replace
Make sure to position the clamps so you know you can get the clamping tool on them in those tight quarters

[78F350]

After reading all the horror stories, I was disappointed with how easy mine was when I did it.
These two two threads were very helpful:
http://986forum.com/forums/diy-project-guides/56334-diy-coolant-tank-replacement-under-2-hours.html
http://986forum.com/forums/diy-project-guides/50261-another-coolant-tank-replacement-diy.html

Here's notes from when I did mine:

Notes:

• Disconnect the oil fill tube in the engine compartment first. Less stress on the hard plastic portion.
• One of the rubber hoses has a quick disconnect in the engine compartment. Easy to use that and get the clamp after it's all out.
• Use flexible hose clamp pliers.

The oily grit is probably left over from the blown and partially disconnected AOS when I bought the car. That's a hard to see/clean spot. The bottom 3 hoses came off pretty easily from here.


The last hose could be pulled into the trunk far enough that it was easy to remove after everything else was freed.


Here it all is, with the tools I used.


It was not bad at all. For the installation, I put all the hoses on the manifold, then pushed them through to the engine side. Easier to reach the hose to hose connections. I tried using a screw-type hose clamp. Bad idea. It is so much easier with the original clamps and hose clamp pliers. I wore 7 Mil nitrile gloves and didn't lose any skin or blood. Topped it off with Peak Long Life that I had picked up on the way home from the track. No need for the pink stuff in this car.

Lastly, many people have tried to save a little money buying a cheaper coolant tank. Many of those people have posted their regrets.

[Brian in Tucson]

Originally Posted by 78F350

After reading all the horror stories, I was disappointed with how easy mine was when I did it.
These two two threads were very helpful:
http://986forum.com/forums/diy-project-guides/56334-diy-coolant-tank-replacement-under-2-hours.html
http://986forum.com/forums/diy-project-guides/50261-another-coolant-tank-replacement-diy.html

Here's notes from when I did mine:


Lastly, many people have tried to save a little money buying a cheaper coolant tank. Many of those people have posted their regrets.

I got a really cheap expansion tank. $49.95 or so shipped. From Amazon. So far it's worked out really well. Guess I've been lucky. NLA, btw. But there is this:

https://www.amazon.com/Genuine-Porsche-Radiator-Coolant-Expansion/dp/B00AGR9XLE/ref=sr_1_3?ie=UTF8&qid=1523285780&sr=8-3&keywords=Porsche+boxster+expansion+tank

Mine wasn't so easy the first time, the Porsche factory elves seem to get a perverse delight installing those spring clamps pointing the wrong direction so they're impossible to compress. I put it back together, with a new oil fill tube and a new dipstick tube. Reused all the spring clamps except the two that go to the metal coolant tubes (replace those rubber hoses,) those were brand new worm drive clamps, the best I could find. Makes getting it all loose again more of a piece o' cake. In case my cheap coolant tank needs replacing in 4 or 5 years.

[njbray]

I think I will give it go!
I may get a new oil filler tube as mine looks oily.
Did anyone replace the temp sensor?
I also thought about replacing water pump at same time but is in only 3 1/2 yrs/23,000 miles old (replaced with IMS) so if looks ok it can wait until next time.
Of course I will get the real Porsche tank!

Thanks for all the advice.

[Starter986]

Originally Posted by Brian in Tucson

I got a really cheap expansion tank. $49.95 or so shipped. From Amazon. So far it's worked out really well. Guess I've been lucky. NLA, btw. But there is this:

https://www.amazon.com/Genuine-Porsche-Radiator-Coolant-Expansion/dp/B00AGR9XLE/ref=sr_1_3?ie=UTF8&qid=1523285780&sr=8-3&keywords=Porsche+boxster+expansion+tank

Mine wasn't so easy the first time, the Porsche factory elves seem to get a perverse delight installing those spring clamps pointing the wrong direction so they're impossible to compress. I put it back together, with a new oil fill tube and a new dipstick tube. Reused all the spring clamps except the two that go to the metal coolant tubes (replace those rubber hoses,) those were brand new worm drive clamps, the best I could find. Makes getting it all loose again more of a piece o' cake. In case my cheap coolant tank needs replacing in 4 or 5 years.

It shows $189.

?

[seningen]

Originally Posted by 78F350

After reading all the horror stories, I was disappointed with how easy mine was when I did it.
These two two threads were very helpful:
http://986forum.com/forums/diy-project-guides/56334-diy-coolant-tank-replacement-under-2-hours.html
http://986forum.com/forums/diy-project-guides/50261-another-coolant-tank-replacement-diy.html

Here's notes from when I did mine:


Lastly, many people have tried to save a little money buying a cheaper coolant tank. Many of those people have posted their regrets.

Can we make this a sticky!

[njbray]

Another Question!
Has anyone experience of using a Coolant Air purge / Refill tool? - such as 'Schwaben 003466SCH01 Coolant Refill/Air Purge Tool'

Seems like a good idea and easier than than all the engine revving method.

[rp17]

Good job congrats!!!

[marcoc]

I replaced my tank about a year ago. I bought an OEM tank from Amazon, around $330 give or take. It had the Porsche part number so I had a good feeling it was a real oem part. As of today its all good. My original tank had a few hairline cracks which presented themselves once the car cooled down. I documented the install with many pictures for my records if I ever decided to sell the car. The install was a bastard of a job. I have done 90% of the repairs on my car and this was the worst period. The hoses behind the firewall were a nightmare to reinstall. I replaced various clamps with better stainless clamps. I used a hose clamp tool but that wasnt the end all tool. The only way to get to those connections was to twist your arm/hand to get in there. A small inspection mirror was the only way to confirm the connections were good. Honestly I pray not to ever do it again, if I ever have to I will pay my local Porsche mechanic to do it. I used every curse word while doing the install, I think the install drove me to drink lol.