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Thats the one. My expansion tank cracked in almost the exact same area. Following the Pelican guides really helped, especially when it came to lowering the engine a couple inches. Don't be fooled by anyone who says you can get it out without lowering the engine, I most definitely couldn't!
I installed the expansion tank today in like 2 hours thanks to everyone’s help here. Thanks. I love the ratcheting hose clamp tool as it makes it so much easier. Dropping the engine is a must and if you drop it farther than you think it should be.....it makes it a lot easier to get out.
I smelled the sweet coolant when I got back from work. Must have been a drip that turned into something more.
Because I went out for dinner with a friend and came back to find a big leak on the garage floor similar to the picture above. This will be the second replacement tank on this car in about 5 years.
To be honest, this looks to be a poorly designed part. It appears that most of the failures are all on the same place just above where there is the outlet. Seems to me it's a poor manufacturing process maybe using injection molding where it's structurally weaker in that spot.
I'd say totally redesign to remove the "honeycomb" to make one big smooth surface, but it leads me to believe, they must have multiple places for injection, and the sides were each honeycomb meets is a natural point to restrict flow of whatever material they're working with.
After years of similar problems, you figure Porsche or manufacturer would redesign the tank at least in two ways: 1.) More material being injected in that chamber of the "honeycomb", or a totally different material 2.) A slightly different shaped tank / possibly smaller to allow for easier re-installation.
If anyone in the bay area wants to advise/supervise, I'd love to tackle this project in about 2 weeks...
Great info, thanks for this writeup! This is a perfect timing for my project. -My coolant reservoir level sensor wire is not connected on the tank for some reason and I can't seem to find the plug. Can you confirm if the wire follows the path I highlighted (green) in the picture below? Does this wire stem from the wiring harness in the left rear quarter panel (o2 sensor + trunk latch release harness, I believe)? Any info regarding this would be tremendous. Basically I'm trying to chase down the wiring loom that carries this connector.
Thanks again
Last edited by RSR23; 09-14-2018 at 11:30 AM.
Reason: Adding picture
07-26-2018, 10:58 PM
