996 T Coolant leak, "odd" location, anyone BTDT?

[996TT02]

As per pic, I noted a leak and while it manifests itself (dripping) further forwards in the vehicle, I am thinking that this is due to the water running along the underside of the pipe/s. Rads etc fine, new, easy to check, not anywhere on the suspects list. I studied the drips etc and hopefully my investigation and subsequent theory is correct.

As above if I am correct the leak seems to be somewhere around the join between the rubber Y piece and the metal (thought it was plastic!) pipe that goes forwards to the middle radiator.

The hoseclip is in the most godforsaken location known to mankind, I am looking at removing the PAS hoses just to be able to access this.

I wonder whether anyone has had problems of the sort in this location or can offer any other usable advice of whatever form.

Thanks in advance, I am a bit peed off seems I spend 4 days driving and 4 days spannering. Only positive is that I hope that the previous mysterious drop in coolant level in the expansion tank has now had it's cause identified. As an aside I may have a small leak from the black cap of this latter, anyone serviced this, should be easy to replace o-rings I assume?

[Homer J]

Alright Mate,

I had the majority of my coolant pipework replaced in November. Including the area you mention above.

I had it done as part of my rolling restoration on my car so I was having the diff and steering rack removed anyway for overhaul. When we looked at all these lines we found they were well past there best.

The 2 x main feeder lines which runs from the engine, down the centre of the car to the rads were replaced as well. These go from aluminium to rubber tubing round about the steering rack. When we un-coupled the clips for the tubing we found the aluminium was worn down to almost nothing, actually holed in places. This could be something else to look at replacing while your there.

Obviously having the rack and diff off made things a hell of a lot easier access wise.

Not pics unfortunatly.

[Crimp a Length!]

I get a smell of anti-freeze when i have been on a run.
The level never drops in the expansion tank as i religiously always keep an eye on this as i have with all previous water-cooled 911's. There are also no apparent leaks around the rads, so i'm totally confused as to what is causing it??

[996TT02]

After an afternoon spannering effectively taking apart all the cooling system in the front drivers side corner (including 2 of the friggin' rads for the umpteenth time) inspecting the prime suspected area revealed sweet F-A.

The ally pipes are as near perfect as matters nowt, the rubber likewise, etc etc.

BUT - I realise that the leak may have come from further forwards and the drips were obviously blown back by the airflow while driving, and there is one location that is showing pink.

It's where the rad lower rubber pipe joins up with the ally. This rubber pipe I have recently replaced, genuine Porsche part.

So what's up? Well, the pipe is different in construction to the "old" one. Sticking to what is relevant, because there are other differences - the wall thickness is 3.5mm, whereas the old pipe and all other pipes have a 4mm wall thickness. That means that the total difference in OD due to the wall thickness is a 1mm reduction. Resulting in less sealing pressure from the non adjustable (and relatively unstressed) clamp on hose clips.

Goddam friggin (insert all expletives here).

Have taken apart half the frontside of the car and it's probably a goddam friggin (insert all expletives here) stupid genuine Porsche hose. Tomorrow I will re-install the lot and use a normal screw type hoseclip to apply the required sealing pressure to the reduced OD pipe. And hope that's the end of it. Well, apart from removing the black expansion tank bleeder cap and servicing it, if possible, and replacing 2 track rod ends (one needs it other has done identical mileage so...)

And hope that the door lock won't play up, all seems well.

Maybe one day I'll even get to drive this thing, who knows.

[kev b]

You have my sympathy, more and more I am coming across needlessly complicated updates to components that have worked perfectly for half a century or longer.

Jubilee clips are a fine example - cheap, simple, reusable, need no special tools, adjustable in service, easily available, stocked everywhere, a few sizes fit most applications.....

Now not only are there half a dozen different types of clip but some won't even allow you to replace them with a jubilee clip when they are destroyed on removal and then it takes a day or more to source a replacement. What were they thinking?

[Henry-F]

I'm not sure exactly which bit you changed. Just make sure that the parts you ordered from the main dealers aren't handed left and right and you have the wrong side ie. left not right or visa versa.

Almost identical but not quite.

Henry

[996TT02]

Henry-F said:

I'm not sure exactly which bit you changed. Just make sure that the parts you ordered from the main dealers aren't handed left and right and you have the wrong side ie. left not right or visa versa.

Almost identical but not quite.

Henry

Rubber hose from side rad lower to metal, not in pic.

Issue is wall thickness, not fit.

Even the collar with o-ring that fits the rad is now different, material was aluminium, now can't tell, it's thinner and looks more like galvanised steel.

Supplier possibly changed and perhaps Porsche know that the hose clips also need changing but perhaps difficult for the spannerman to know.

All assyd now perhaps will test tomorrow.

Either way not totally wasted effort, a lot of attention given to preventing and stopping light corrosion in places.