Coolant leak repaired

[porscot]

If I am not mistaken this is the same problem as my 987 2.7 Boxster. Apparently it is a common problem and it is almost always the same hose. Stuart at SP Autobahn in Stirling knew which hose before I even showed him the car. As it is only a minor drip I left it for now. The problem seems to be with the design of the connection at the joint. The hose does not cost that much (£30 or so as I recall) but obviously need to add on cost to top up coolant. Regards Graeme

 

[Contraband]

Advice please..
I have just changed the disks and pads at the front tonight. I noticed I have a bit of a leak on the lower hose. I take it this is the return from the radiator as after a run it is cool to touch and pressurised.

Is this a common fault? Can it be tightened at all? I have forgotten the name of that type of clip but it does not look like it could be replaced with a different adjustable type... Or can it?

Archie.

 

[GreigM]

I think Graeme is on the money there. It is a cheap hose replacement, so long as your coolant level isn't dropping fast and you keep it topped up you could keep going until the car is due a coolant refresh. The most difficult part about the job is making sure the coolant system is properly bled, otherwise I'd be suggesting a DIY fix as it really will be very simple.

 

[Contraband]

It's more of a drip than a leak, but it will need fixed at some point. When the engine was hot, the hose was pressurised and i was pushing and pulling it and nothing was coming out. I am all for the DIY fix. I was hoping I could cut the clip/clamp off and replace with an adjustable one. I should have had a better look when the wheel was off as I can't remember if the hose went into a hard plastic fitting or a soft one. Hopefully soft so it can be compressed with a new clamp. Archie.

 

[GreigM]

I like you're spirit - too many people are afraid to fix something like a simple hose leak. It LOOKS like a moulded plastic fitting on the interior side, but if not I'd have it out, insert an aluminimum joiner and get busy with a couple of jubilee clips. Even if it it a moulded fitting, I wonder if you put a jubilee on the outside and just nipped it up enough to put a light pressure on the join if that would stop the leak without having to change anything....worth a try.

 

[John H]

I had this leak on my car (2006 2.7 Cayman) although it was fixed for me by the OPC as the car is under extended warranty. As I recall it is caused by corrosion at the end of that pipe, which is known as a transfer pipe as it runs across the car. Not sure if the OPC guys replaced the pipe, I suspect they did. Not a huge part, but I gather it is not the easiest thing to get at. Best of luck. Edit ... why not phone the guys at Edinburgh Porsche and ask their advice, as clearly they know this as a fairly common problem. I'm sure they'd advise you, especially if you have to buy a replacement pipe from them. Scott Fraser (service advisor) or Max Fisher (service manager) are always helpful to me. Granted I'm a customer, but they also offer me DIY advice too.

 

[Contraband]

Thanks John. I am downloading a cayman workshop manual just now as I want to know exactly what is involved in repair or replacement. I am thinking there is some sort of insert in the pipe that has corroded and is causing the leak. I really actually enjoy working on my cars and would normally always carry out repairs myself. With only having had the cayman for a few months I have not yet had to get in about it.. Apart from disks and pads. I will probably pop into the OPC service dept. and enquire about buying the parts required... And see if any free advice is offered! Archie.

 

[John H]

Ah, mention of the insert rings a bell, I seem to recall that being mentioned. Either the pipe or the insert is aluminium I think, and was corroding.

 

[Contraband]

Got the new part. The picture shows that it is sealed with an o-ring and held in place with a clip. Fitting looks straightforward, just got to bleed the cooling system when done. OPC spares chap tells me this is a very common part to fail. Once fitted I think some grease around the outside might help extend its life..

 

[Contraband]

Ok, so I eventually got round to doing this job today..... The leak had just got too annoying. Jacked up, wheel off and a basin to catch the coolant. I decided not to drain the system and hoped I would not lose too much coolant. I then took the plastic wheel arch liners out... Just a few screws. This now exposes the other end of the pipe.

I then used a screwdriver to release the retaining spring and pulled the higher end out first. Only lost about 500ml at this point.

Then the corroded lower end. About another 500ml in total came out...

You can see the state of the connector here... No wonder it was leaking. The new one is on the left...[]

I fitted the new pipe with a bit of instant gasket just to be on the safe side and pushed the clips back on... Job done. I will top up and bleed the system through the week. When I am sure there are no more leaks I am going to put grease around the collars of all the exposed pipe fittings as this problem has been caused purely by corrosion from exposure to water coming from the wheels. The grease should waterproof them a bit.... Happy days... Time for wine.

 

[Contraband]

That's the system bled now and the car has been take for an hours "spirited drive" and it's leak free. I saw my engine for the first time today. I had to remove the covers to bleed the system. You can see the blue filler cap for the water on the right......

 

[Mike58]

Nice pics, always good to see some straightforward repairs. The state of the original pipe end makes you wonder about the condition of the others and on all our cars. Oh to be in a country with no salt on the roads and some nice dry warm weather....

 

[2fast4u]

Hate to think what you would have been charged for that!!

 

[996_STEVO]

You didn't use instant gasket on the rubber seal?

 

[Contraband]

Blue instant gasket was used on both ends... You can see a bit of it here..

 

[996_STEVO]

ok on the alloy surface but the rubber seal should only have the slightest smidgeon of grease so it slips nicely in as this expands due to heat and forms your seal, if you have sealant on this it will harden and might not seal when it eventually breaks down, don't get me wrong it might be fine!

 

[Contraband]

The rubber seal has nothing on it. The blue non hardening instant gasket was put around the collar only just as a secondary defence, as much to stop crud getting in as water getting out...

 

[996_STEVO]

ORIGINAL: Contraband The rubber seal has nothing on it. The blue non hardening instant gasket was put around the collar only just as a secondary defence, as much to stop crud getting in as water getting out...

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