Radiator & condenser replacement Boxsyer S

mic · Aug 2, 2009

Hi,
I new the day would arrive when I needed to replace the AC condenser's on the Boxster S ( been hoovering the ducts out every 6 months for a while now and they have lasted a year longer than I thought). What I did not expect the check over report from the garage at the last MOT to also highlight was 2 new radiators required as well.
As an ex Technician for another prestige european manufacturer and having changed condenser's on 911's before will probabaly do the job myself. Although I have heard that Boxsters are very difficult to bleed after radiator changes, is there any one out there who might know where I can get a copy of the procedure and any special tools to change the rads and bleed, also might as well brush up on the condensers replacement method as well.
Any help or links appreciated.
Thanks in advance.

Mic

Mark_Bennett · Aug 2, 2009

From something I'm currently writing...

The long run from radiators at the front, to engine in the middle of the car can mean air locks can occur if you just top up at the coolant filler, if this happens follow this process: In the rear boot remove the coolant cap, and the oil filler cap (make sure the engine is cold first to prevent possible injury from boiling coolant). Lever up the trim cover underneath the filler necks. Flip up the coolant bleeder valve locking clip. Replace the Oil filler cap For automatic transmission cars, remove the fuse B1 in the fusebox "" this disables the shut off valve for the ATF cooler. Fill with the 50-50 coolant-water mix. Fill to the Max line in the level indicator. Run the engine at idle, continue to top off the coolant until no more can be added. Note: Do not allow the coolant o exceed 80 Degrees C (176F). Replace the coolant cap and tighten. Let the engine warm up for 10 or so minutes at 2500rpm. When the engine is fully warmed up the radiator cooling fans will come on. Run a further 5 minutes at 2500rpm, and blip the throttle now and again to 5000 rpm. Cover the coolant reservoir cap with a thick cloth and open slowly, releasing the pressure carefully "" Do Not scald yourself! Top up the coolant, close the cap again, and repeat the process for a further 5 minutes, reving intermittently to 5000 rpm. Idle the engine until the radiator fans have cycled on and off once, then switch off the engine and again carefully remove the reservoir cap, taking care to relieve the pressure slowly. Top up the coolant until it is at the MAX mark on the level indicator in the rear boot. Flip the coolant bleeder valve locking clip down again. Replace the filler neck trim cover and all caps. Replace fuse B1 on automatic transmission cars.

drgav2005 · Aug 3, 2009

A quick modification can be done which will significantly reduce the 'detritis' that accumulates in front of the condensors - hopefully increasing their lifetime:

Check out the following: http://www.boxa.net/forum/index.php?showtopic=39747

Hope this helps! [

]

mic · Aug 3, 2009

Hi Mark, thanks for the info, sound like a fairly straight forward method, nearly the same as most mdern cars but with the addition of the rear blead valve which I am guess will be more straight forward once the trim covers is off and it can be seen by eye.

Like the look of drgav2005 mod, may be even easier to fit once the bumper cover is off on the 986. The mod has the added plus of protecting the units from larger stones and debris that litter our roads after the major pot hole season most of us have just driven through. It pretty discreet too..

Now just need to source the condensers, radiators and coolant at a good price as at present getting all sorts of prices, if any one knows of a good suppler of these parts for a 986 S 02 let me know what the going rates are.

Many thanks
Mic

berty987 · Aug 7, 2009

There are also proprietry grilles available from zunsport in either chrome or black that go over the front intakes. The mod on the link is a follow up to the modification I carried out my own car and involves making up your own grilles to place behind the original slats. Either option should increase the life of the front radiators especially for those cars kept outside and driven daily.

paul hunter · Aug 15, 2009

mic
i need to do the same but have been quoted £800 just for the condensers (supply, fit and regas). where did you buy yours? how much? are second hand ones available? any recommendations for used parts suppliers?
regards
Paul