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Section 4 (Specifications & Drive Belt Routing): Servicing

WARNING: This page is about a different car, the 2004 Porsche Boxster and 2003 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Cooling system is pressurized, when engine is at operating temperature. Use caution and use other appropriate protective gear when servicing cooling system. Slowly and carefully release system pressure, before performing any repairs.
  1. Start engine, and raise engine speed to medium RPM for at least 15 minutes, or until coolant temperature is less than 176° F (80° C).
  2. Turn engine off, and allow to cool. Carefully open expansion tank cap. See Figure . Drain cooling system. See DRAINING, FILLING & BLEEDING COOLING SYSTEM  under DRAINING, FILLING & BLEEDING.
  3. Fill cooling system with water, and bleed system. See DRAINING, FILLING & BLEEDING COOLING SYSTEM  under DRAINING, FILLING & BLEEDING.
  4. Start engine, and raise engine speed to medium RPM for at least 15 minutes, or until water temperature is less than 176° F (80° C). Turn engine off, and allow to cool.
  5. Drain cooling system. See DRAINING, FILLING & BLEEDING COOLING SYSTEM  under DRAINING, FILLING & BLEEDING.
  6. Replace all hoses, which have been removed during cooling system draining. Replace Y-piece on vehicle underbody. See Fig 1 .
    Fig 1: Locating Y-Piece On Underbody
    G00304570Courtesy of PORSCHE OF NORTH AMERICA, INC.
    7. CAUTION: Coolant hoses may only be coated with water, to aid in installation to flanges. Never treat coolant hoses with spray oil
  7. Using a clean cloth, soaked in naphtha solvent, clean flanges of coolant circuit. Connect NEW coolant hoses to flanges, and tighten hose clamps.
  8. Install coolant drain plug with NEW O-ring. See Figure . Tighten drain plug to 88-132 INCH lbs. (10-15 N.m). Fill cooling system with sufficient amount of coolant mixture. See COOLING SYSTEM SPECIFICATIONS  .
  9. Bleed cooling system. See DRAINING, FILLING & BLEEDING COOLING SYSTEM  under DRAINING, FILLING & BLEEDING.
  10. Check cooling system for leaks. Perform extended test drive with vehicle. Check coolant level, and top off as necessary.
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