My '03tt dumped coolant yesterday in a big way just cruising along. Just a little squeek squeek squeek (from the belt?) and the check coolant light coming on. Immediately pulled over and had a puddle under the car. Towed it home last night. The expansion tank looks fine. When I pour water in, is comes out IN A HURRY somewhere on the top of the driver side bank. I pulled the air filter housing and the bottom of the tank & lines are all fine. There appears to be 3 lines from the water pump running up and over the motor under the manifold. My best guess so far is one of those split in a huge way or a clamp worked off. So my questions are:

What do those lines go to? It looks in PET two might feed the water heater lines but I can't really tell.

How much of a pain is it to get to those? Can it be done from the top or is a motor drop prudent?

Are there other more likely sources that it'd be leaking from? I can't even sneak a borescope in to see where the leak is. That stuff is packed in there.

 

Take a good look a little further forward. I saw once a strong leak coming from these seals...see pic...The pipe was not line up properly with the casting and finally damage the seals.

 

LOL. Easier said than done Im guessing I have to pull the alternator (and thus the Y-pipe) to see anything further back?

This is more than a "strong leak" If I pour 1/2gal into the tank, most of it will be on the floor in ~20s. It just floods over the left bank. Thats why I think a line blew off. Its got to be a big hole.

 

In fact it is a big hole !!! But with a mirror at the end of a 12 inches handle I was able to inspect this area.... But being sooo big of a leak may be it is a blown hose....

 

Consider dropping the motor a bit (tilt) to give you a bit more space to inspect. May need to drop totally, but a slight drop is pretty easy to do.

 

As mention by Ard, lowering the engine is a smart move see link:https://www.6speedonline.com/forums/...tt-engine.html

 

Tnx. I've rebuilt oil cooled 911 motors so this one shouldn't be too different.

What *REALLY* sucks: I have a new lift. Can't use it because the wife's boxster is stuck up there w/o a trans so Im doing mine in the driveway. If I have to drop this motor, Im yanking hers off *MY* lift

 

I'm sure you won't tell us who's going to win that one.....

Let us know your findings....

 

dropped the motor a little and used a mirror & borescope to look around. I could SWEAR I see the open end of the hose way back near the flywheel using the scope. I tried from underneath near the trans and can't see or feel it though. Even if I do find it, there is no way Im going to be able to repair it so either I have to take a bunch of stuff off the front/top of the motor or the motor has to come down & out Makes an couple hr expansion tank problem seem minor.

 

To situate you may be those pictures can help....

 

Thanks jp, those pics help a lot. The pic from PET, I can see the heater hard lines 19 & 21 in your pic too. Im wondering if its one of the short hoses 20 or 23.

From your more top view looks like a bunch of stuff is going to have to come off. I pulled the bolts for the alternator but the right side of it won't wiggle free easily. I need to search/read up more on if I get it free are the wire going to be slack enough to pull it fwd (at least enough to then possibly disconnect it.) Looks like that *MIGHT* give me an access window.

 

I guess you got access to the repair manual If you do, remember Porsche call it a Generator. To facilitate your search.... Page 643.

 

Yes, I have the manual. Gave it another go after lunch (and a nap I finally got the gen moved fwd. FWIW, If that aluminum bushing on the right bolt hasn't moved in 7 yrs no amt of "gentle tap"ping is going to get it to move back I eventually wiggled/pried it and up and over. There is plenty of wire to pull it fwd w/o disconnecting. The loose fitting was then staring me in the face...

Now how to fix it! The elbow appears to have been bonded orig. Wonder if I can rebond successfully (and w/ what) or should I just replace the whole housing.

 

I hope someone will jump in because this seems to be a problem other people ad in the past.... I think a tuner mention it in his thread, saying to do it while the engine is out!.... I will do some research....

 

Take a look at this subject: https://www.6speedonline.com/forums/...coolant-2.html


No I don't think it is the same thing