Coolant tank failed.

[el 3.2S]

Well, three years into Boxster ownership, I appear to have my first mechanical failure. Today I finally investigated my erratic coolant leak and found out that the expansion tank seems to have split. I recently replaced the cap with an 04 model.

I cannot see where the coolant comes out as it is round the back, but with the engine running, I observed drips coming from that side. A bit of internet research proved a little depressing due to the cost of a new tank and especially the apparent nightmare job to change it. Wondered if anyone had managed it with normal tools, or are specialist items required? Also, how many hours would the dealer use for this job?

The fleet today, with the Boxster very much in the shade as it joins the Vectra in being off the road and not useable. Mind you with an average age of 17.5 years, it is perhaps no wonder. Nearly the same fleet age as Jet2 lol. Just hope the Ml does not let me down.

 

 

 

[JohnnyUK]

I bought a second hand, but reasonably new tank as I had the same erratic loss of coolant. I also bought a spring clip plier to help undo the clips.... Yep it looks a bugger to swap as the difficult connections are on the engine side of the bulkhead. didn't have to do the job as it turned out to be the pump. Would you be prepared to tackle the job yourself? 

[el 3.2S]

37 minutes ago, JohnnyUK said:

I bought a second hand, but reasonably new tank as I had the same erratic loss of coolant. I also bought a spring clip plier to help undo the clips.... Yep it looks a bugger to swap as the difficult connections are on the engine side of the bulkhead. didn't have to do the job as it turned out to be the pump. Would you be prepared to tackle the job yourself? 

I am not sure I have the required skills for this job, was curious to see what others on here have done. Lack of quality independant garages round here may mean a trip to the dealers which is not terribly appealing.

[ooid]

A bit difficult job, I got it replaced by my indie 2 years ago. It needs a proper bleeding though! There should not be any air in the system but once it's clear , with new tank and coolant it's fantastic.

Would be good if you can also inspect the older tank, see any small oil contamination? I I see in your pictures, there is a bit of yellow-brownish colour in the tank? coolant usually should be only pink. If you think there is oil in there, A further look into oil cooler or cylinder heads necessary I'm afraid :/ 

[Boxob]

1 hour ago, ooid said:

Would be good if you can also inspect the older tank, see any small oil contamination? I I see in your pictures, there is a bit of yellow-brownish colour in the tank? coolant usually should be only pink. If you think there is oil in there, A further look into oil cooler or cylinder heads necessary I'm afraid :/ 

Porsche coolant used to be green now it's pink. If previous owners topped up the older green coolant with the newer pink coolant then the resultant mix would probably be brownish. Hope that's the explanation!

[Terryg]

I had the cap replaced and shortly after the tank split, I am pretty convinced there is a connection. Revolution replaced mine so I can't comment on the ease of fitment.

[ooid]

8 hours ago, Boxob said:

Porsche coolant used to be green now it's pink. If previous owners topped up the older green coolant with the newer pink coolant then the resultant mix would probably be brownish. Hope that's the explanation!

Indeed, we are only speculating by looking at the pictures!! Hopefully, the coolant is pure clean.

I'm really jealous of the el 3.2's garage situation though. I tried to export my boxster to Barcelona last year, where some of my family lives. So I would be able to use during holidays. It was a bit complicated and was busy with work so much, had to sell it at the end.  

Spain, especially Barcelona is a great place to enjoy these cars. Massive roads, not much heavy traffic even in urban areas and loads of fun roads outside city  

[el 3.2S]

Thanks for replies. Never seem to manage the multi quote bit . Glad to say there is no oil in the coolant. Maybe the old style caps kind of fail and in doing so, protect the tank from cracking?

It is perfect Boxster weather here now, sunny, no wind and not too hot with day temps in low 20's. Bad time for it to be off the road. Too many cyclists though lol.

Looking at the three coolant pipes going into the bulkhead, it appears that they can all be disconnected from the expansion tank side, as per this picture, top two have clips and the bottom one does not. Large one at the top is for oil. Are there other pipes which cause the problems and have to be disconnected from the other side?

 

[el 3.2S]

Won't let me edit my last post now but just seen a picture with the other line from the tank which has to be disconnected on the engine side .

[Boxstercol]

I don't know much about the set up of the coolant tank, but shouldn't the bottom hose also have a spring clip on it?

Might be worth checking, in case this is the source of the leak when the system is pressurising.

[Boxob]

13 minutes ago, Boxstercol said:

I don't know much about the set up of the coolant tank, but shouldn't the bottom hose also have a spring clip on it?

Might be worth checking, in case this is the source of the leak when the system is pressurising.

Good spot. Just checked the parts diagram and yes there should be clips at both ends of that hose. 

[JohnnyUK]

The tank itself has a separate connection on the engine side of the bulkhead. You can get access, limited, by popping out the rubber grommet next to the manifold. A suggestion was to release the relevant hoses at the engine where there is more access and not St the bulkhead end where there is none!? Glad I didn't have to try!

[kevs]

Mine hasn't failed so I have no personal experience (nor the skill to do it myself) but I do have a copy of 101 projects for your Porsche Boxster which has a section on this.

The projects are actually published on the Pellican Parts website so you can just check the following link which has step by step instructions and pictures for doing it yourself:

http://www.pelicanparts.com/techarticles/Boxster_Tech/33-WATER-Coolant_Tank/33-WATER-Coolant_Tank.htm

[el 3.2S]

1 hour ago, kevs said:

Mine hasn't failed so I have no personal experience (nor the skill to do it myself) but I do have a copy of 101 projects for your Porsche Boxster which has a section on this.

The projects are actually published on the Pellican Parts website so you can just check the following link which has step by step instructions and pictures for doing it yourself:

http://www.pelicanparts.com/techarticles/Boxster_Tech/33-WATER-Coolant_Tank/33-WATER-Coolant_Tank.htm

Thanks for the reminder, I forgot I had that book. Going to have a look at it.

2 hours ago, Boxstercol said:

I don't know much about the set up of the coolant tank, but shouldn't the bottom hose also have a spring clip on it?

Might be worth checking, in case this is the source of the leak when the system is pressurising.

Interesting, wonder why they are missing? Will have another check just to be sure it is the tank itself. Would hate to get all this done if it were not needed!

2 hours ago, Boxob said:

Good spot. Just checked the parts diagram and yes there should be clips at both ends of that hose. 

Thanks for confirming.

1 hour ago, JohnnyUK said:

The tank itself has a separate connection on the engine side of the bulkhead. You can get access, limited, by popping out the rubber grommet next to the manifold. A suggestion was to release the relevant hoses at the engine where there is more access and not St the bulkhead end where there is none!? Glad I didn't have to try!

I read somewhere about that. Possibly slightly easier but most likely still a bit of a nightmare!

1 hour ago, kevs said:

Mine hasn't failed so I have no personal experience (nor the skill to do it myself) but I do have a copy of 101 projects for your Porsche Boxster which has a section on this.

The projects are actually published on the Pellican Parts website so you can just check the following link which has step by step instructions and pictures for doing it yourself:

http://www.pelicanparts.com/techarticles/Boxster_Tech/33-WATER-Coolant_Tank/33-WATER-Coolant_Tank.htm

 

[Terryg]

My cap was changed as a precaution and on the drive back from the garage that changed it the tank split and spilt coolant into the tank. Coincidence? Possibly but I don't think so. Conspiracy to clear a surplus of coolant tanks? Hell no!!"!

[Terryg]

Just now, Terryg said:

My cap was changed as a precaution and on the drive back from the garage that changed it the tank split and spilt coolant into the tank. Coincidence? Possibly but I don't think so. Conspiracy to clear a surplus of coolant tanks? Hell no!!"!

Sorry that should have been "into the trunk"

[el 3.2S]

10 hours ago, Terryg said:

My cap was changed as a precaution and on the drive back from the garage that changed it the tank split and spilt coolant into the tank. Coincidence? Possibly but I don't think so. Conspiracy to clear a surplus of coolant tanks? Hell no!!"!

That is spookily similar to me. Tank failed within a very few miles of changing to a newer cap. Wish I had not bothered now lol.

[edc]

Its a bit chicken and egg. The tank gets brittle and will crack. The cap loses its ability to hold the pressure. The car runs hotter and the cooling system becomes more and more inadequate. It will likely reach a critical point where the cap can no longer hold enough pressure and as the car reaches operating temperature, either in normal running but more likely in traffic, hard driving or just after being parked up, as there is not enough pressure the and the cap is weak the relief valve will purge the system. 

[Menoporsche]

Yes, this sounds logical. As parts get older they fail. If pressure can't get out one way, it will get out the other!

Maybe we should recommend that from now on (as all 986 are 12 years old or more) people should consider replacing their coolant tanks at an opportune moment, a bit like the parallel discussions on water pumps.

[Terryg]

39 minutes ago, Menoporsche said:

Yes, this sounds logical. As parts get older they fail. If pressure can't get out one way, it will get out the other!

Maybe we should recommend that from now on (as all 986 are 12 years old or more) people should consider replacing their coolant tanks at an opportune moment, a bit like the parallel discussions on water pumps.

Yep I think that makes sense, we are recommended to change the cap as a cheap and quick precaution but it doesn't end up that way, much better to recommend changing both and then people will know what the are in for.

[ooid]

1 hour ago, Menoporsche said:

Yes, this sounds logical. As parts get older they fail. If pressure can't get out one way, it will get out the other!

Maybe we should recommend that from now on (as all 986 are 12 years old or more) people should consider replacing their coolant tanks at an opportune moment, a bit like the parallel discussions on water pumps.

Totally agree. Any 10+ years old car with flat 6 or higher, ideally you could renew/update the whole coolant system. Radiators, Fans, Water pump, thermostat, Coolant tank and new cap. Flush the system, good to go. I think this complete cooling overhaul should not cost more than 1.5k done by a qualified indie or DIY. 

Many people spend more than that on cosmetics such as detailing but this is a very critical update for boxsters I think, for a trouble-free motoring.  

 

 

[el 3.2S]

On 20 de noviembre de 2017 at 8:39 PM, Boxob said:

Good spot. Just checked the parts diagram and yes there should be clips at both ends of that hose. 

Strangely, I have seen several used tanks for sale on e bay without a clip on that third hose.

[Boxob]

16 minutes ago, el 3.2S said:

Strangely, I have seen several used tanks for sale on e bay without a clip on that third hose.

If you Google images of the header tank (whilst fitted) you'll find most images with the clips and a few without. The clincher for me is the parts diagram which shows the clips. Nothing lost if you add clips to test the possibility of the pipe leaking at the joins.

[el 3.2S]

2 hours ago, Boxob said:

If you Google images of the header tank (whilst fitted) you'll find most images with the clips and a few without. The clincher for me is the parts diagram which shows the clips. Nothing lost if you add clips to test the possibility of the pipe leaking at the joins.

Would not do any harm to try but I think the leak comes from the far side of the tank - the part you can't see. Must get motivated and try to sort it, not looked at it the last 2 weeks.

[el 3.2S]

Well things are moving on at a blinding pace. Have bought an extended reach hose clamp tool from e bay uk and have watched the youtube videos. Don't reckon Spain has seen such a thing so no point even looking. A project for next year.....