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mxm1275

Boxster 986 water pump replacement (2.7/ 2003)

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Hello fellow Boxster owners...

I have just replaced the water pump on my 2003/ 2.7 986 and thought I would post my experience to help fellow owners as there seems to be some conflicting advice online.

Just some pointers for those considering doing this task.

Tools required.

  • 10mm spanner (open and closed end)
  • Deep 10mm socket
  • Normal 10mm socket
  • Small cutters (to cut gasket if not replacing thermostat)
  • Normal lifting gear, axel stands etc

Sundries

  • Light emery cloth/ paper to clean surfaces
  • New coolant. I used red/pink non Porsche concentrate (which supercedes the green and blue type)

Advice!

  • Replacement of the water pump do-able by the home mechanic- dont be put off
  • You'll need jack the car up and support to gain access to the middle of the car
  • You'll need to remove the inspection panel behind the seats. I'm average build and I didn't remove the seats.
  • Drain all of the coolant you can in to a bucket for disposal (I used a washing up bowl for space saving)
  • Replace the belt if you suspect the one you have
  • You'll need to cut the new gasket to remove the thermostat bit (save for sometime later) if not using, use cutters
  • Make a note of which bolts go where and replace the pump
  • Top up with new coolant, I used an approximate 50/50 mix ish
  • Locate the bleed valve under the radiator cap plastic panel and lift lever
  • Start engine and bleed by running up to temp
  • If you get an air lock as I did, you'll need to possibly reset the temp error in thr cars memory before the gauge will work again.

Go for a drive, take off the axel stands first.

Good luck.

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Nice post Matt and im sure this gives a few the confidence to attempt the job, wasnt you quoted nearly £600 all in for this at an Indy?

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Certainly saved a few quid... total spend on parts was £220 (pump, gasket and coolant) from Eurocarparts. The pump and gasket was genuine Porsche. Porsche specialist quoted just under £600.

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I've just replaced my water pump on my 986. 

The biggest faff I had was putting the new pump in place without the gasket dropping off or not lining up. After losing my temper and knuckle skin I had a brainwave (for me it's a brainwave). 

I cut the heads off two longer M6 bolts to give a long studs. Screw these in two of the top holes on the engine, hang the gasket and then offer up the pump, fix a couple of the normal bolts in to tighten up the pump, replace studs with bolts, happy days. Then think to myself "why didn't I think of that an hour ago? Why didn't I take pictures?

I removed the driver seat as I carry a few extra pounds and my body doesn't bend like it used to. Wear a head torch. 

 

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To help with getting air out of the system it is useful to leave the back of the car on axle stands with the bleed valve open when you first run it upto temperature with a few revs.

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1 hour ago, Milko said:

I've just replaced my water pump on my 986. 

The biggest faff I had was putting the new pump in place without the gasket dropping off or not lining up. After losing my temper and knuckle skin I had a brainwave (for me it's a brainwave). 

I cut the heads off two longer M6 bolts to give a long studs. Screw these in two of the top holes on the engine, hang the gasket and then offer up the pump, fix a couple of the normal bolts in to tighten up the pump, replace studs with bolts, happy days. Then think to myself "why didn't I think of that an hour ago? Why didn't I take pictures?

I removed the driver seat as I carry a few extra pounds and my body doesn't bend like it used to. Wear a head torch. 

 

I have found in the past to help locate and keep in place gaskets and such light items. Just a dab of grease to make it sticky and it generally holds them. Check that grease will not interfere with the parts in question , but in general it doesn't.

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On 11/21/2015 at 9:51 AM, mxm1275 said:

 

  • Make a note of which bolts go where and replace the pump

A small but important point.  Some of the bolts are longer than others.  I saw a report from another enthusiast admitting that he lost track of the bolts and inserted a long bolt into a short hole.  He continued  tightening the bolt until the head sheared off.  

 

  • Thanks 1

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