jetrainor

Having just completed the dreaded driver door handle inner mechanism change...i left some blood on the inner crash bar.....i'm looking for another reason to drink a few beer. I suspect my coolant level sensor in the overflow tank is not working....my dash idiot light (coolant level) is on constantly. I have the new part for the tank and am wondering if anyone has done a write up on removal of the tank.....ive search the achives and can't find one. It looks pretty tight in there and its always nice to have 'experience' on your side.

87 S4

UKKid35

There are some advantages to having a RHD car...

Ironically I have to do this myself as I've just discovered a leak somewhere around the tank. The large lake of red coolant emenating from underneath my car is a bit of a giveaway - it looks like I've murdered someone!

jetrainor

Hi Ukkid....i had a similar issue with the red fluid i assumed was leaking from my auto tranny or an AT line....turned out to be my powersteering fluid and a busted return line for which there is apparently no replacement parts....none in stock and none at Porsche....will probably have to have it made locally.

john
87 euro auto

docmirror

It's been a while, let me recall. Remove the air cleaner asm. Loosen the front phillips screw to the tank. Work between the two hoses. If there is a pin or screw in the back, remove it. Pivot the tank on the front screw inward, to expose the sensor nut with the sensor wires on top. Gently loosen the large plastic sensor screw from the tank. Slide the sensor post out of hte tank and check the level float.

Replacemnt is the reverse of the above(hahahaha!)

Doc

marton

Actually it is pretty easy, some have 2 bolts and later models 3.

There are lazy people who put the 3 bolt ones back using only 2 bolts... Guess how I know.


basically just undo the bolts and wriggle it out...

Marton
I also did the rite of passage door handle replacement; the tank is much easier

UKKid35

Definitely the expansion tank - it has a split in it...

And it was far more awkward to remove than I remember.

JHowell37

What is the deal on the door handle replacement?

Jim bailey - 928 International

When removing a bad tank "And it was far more awkward to remove than I remember." just use you dremel tool and cut it into pieces ! No need to remove it as one piece

the flyin' scotsman

They break.........its only a matter of time

Jim bailey - 928 International

The door handle is fine but the inner hinged piece 928 537 063 04 a cast metal part does break over time the arm starts to bend crack and you must pull up the outer handle harder and harder ubtil it finally shears off and you are climbing in the rear hatch

jetrainor

I'm just hoping to gain enough room to insert the new level sensor. While i'm thinking of it, is there anyway a bad coolant level sensor could be affecting my temp guage or any other function of the cooling system. Seems ever since the coolant level lite came on permanently my temp guage reads higher and jumps around.
87 S4 euro

jetrainor

and yes, i have checked my coolant level visually.

UKKid35

I just managed to fix the split on the underside of my coolant tank, although no idea how long it will last. I mixed up a generous amount of epoxy resin, and then used a jewellers blowtorch to melt the plastic around the split, then I mixed the epoxy in to the molten plastic. If I'd had some light fibreglass matting I would have added that too.

Took the car for a 5 mile drive and its still holding. Much better than having the car off the road until I could source a replacement.

I do recommend fixing the coolant level sensor, as we can't be too careful with aluminium engines.

Garth S

At this time of year, the expansion tank cap should not be needed to pressurize the system: sans pression, your repair should last nicely ....

Garth S

Do a search under' NAPA- power steering hoses' - somewhere in the archives are NAPA numbers for at least some of the lines: I have a perfect record of them somewhere that is perfectly lost .... will post if they turn up.