[astroede]

I noticed coolant drips on the middle of the sway bar and I had a low coolant level today. No obvious source of the leak, but I can see a little wet coolant in the seam at the very lowest portions of the plastic belt cover, as if coolant was inside (can't see any). I removed the upper belt covers and I don't see any coolant anywhere, even as far down low as I can see in the tangle of belts and pulleys. It is not dripping while sitting. The water pump was replaced 2000 miles and 2 years ago and appears clean everywhere I can see. I did not remove the belts, but they are dry as far as I can tell, as are the radiator and the hoses. I have a very clean engine, so I think coolant anywhere would be seen fairly easily.



I did my first autocross last weekend and I didn't notice anything abnormal. Any ideas? Where should I look that I may have missed? There is not much to describe...the wet spots on the belt cover seam and some drips on the sway bar are it. Help?

Partial Post: Please Login or Register to read the full post.

[rl968]

Look at the connection to water pump

Partial Post: Please Login or Register to read the full post.

[astroede]

Thanks...connection to the water pump looks fine but I will double-check. I pulled off the outer belts and removed the lower belt cover. No trace of coolant on the inside, just a little greasy grime. Perhaps the coolant came from the outside somewhere. I have looked at the radiator very closely, and I don't see any issues. Verified all belts and the front of the engine is dry to the extent I can see/feel it. At this point I am inclined to put the belts, covers and distributor back on and test it running, but I will wait to hear if there is anything more I should look at. RL968, thanks for the response!

Partial Post: Please Login or Register to read the full post.

[Lear35A]

I agree with rl968. Really torque down on the hose clamps at the water pump inlet and discharge.

Partial Post: Please Login or Register to read the full post.

[Cloud9...68]

I once had a leak at this connection:



   



There's an o-ring on the inside that was bad. Worth a look...

Partial Post: Please Login or Register to read the full post.

[astroede]

Thanks everyone for your input. I see no traces of a leak, but I am tightening up all hose connections as suggested. Looks like I will have to reassemble, top up the coolant, and see exactly where this is coming from (hoping that I fixed it). I'll post an update later. Have a safe and fun holiday.

Partial Post: Please Login or Register to read the full post.

[flash]

look for seepage at the heater control valve. i had that happen just before it blew completely.

Partial Post: Please Login or Register to read the full post.

[astroede]

OK, I re-assembled the car after tightening clamps, added coolant, bled it, and here's what happens: At idle, there is a very light drip that eventually stops when the engine is hot, coming apparently off the face of the engine right behind the belt covers underneath the car, in two spots. When I rev the engine, the drips are greatly accelerated...not cool to see that. I'm guessing that points to the water pump gasket? Remember the pump was replaced 2000 miles, two years ago, before I bought the car. Is there anything else on the front face that would not be visible? I see no other leaks. Crap. If this is the water pump seal, how much repair cost am I looking at...and are there any other options or things to try before I haul it in?

Partial Post: Please Login or Register to read the full post.

[flash]

could be the gasket or the seal. either way, the pump comes out.



so, pump and belts (never reuse a belt)



the "good" news is that you were only a year away from needing new belts anyway.

Partial Post: Please Login or Register to read the full post.

[astroede]

Yup, I guess there is a silver lining if there can be one in this situation. And, it happened in my garage, not on the freeway in Timbuktu. Actually, I had never disassembled the front of the engine, so this was a great experience for me personally; I'll know what I am facing next time (and it was very easy work). Thanks Flash and everyone for your input. I'm inquiring about getting it repaired; any preferred repair guys in the South Chicago (Rte 80) area?

Partial Post: Please Login or Register to read the full post.

[Cloud9...68]

If this isn't your daily driver, you have a place to work on it, and a few decent tools, I'd encourage you to try doing it yourself. It's not that difficult (just time-consuming), and with all the people who on this site who have done this job, the "tricks" are well understood, and just a mouse click away.

Partial Post: Please Login or Register to read the full post.

[astroede]

I really would love to do this myself...I have lots of tools, but no "special Porsche tools" like the belt tension tool. I know there has been some documentation here of how to change the belts, and of course Clark's garage DIYs. And as you point out, help is just a click away thanks to ya'll. I'm a mechanical engineer, so I tend to dive right in...and break stuff occasionally trying to do good...but I'm game if you think it is possible without the special stuff. Time, I have.

Partial Post: Please Login or Register to read the full post.

[tamathumper]

Get yourself a 27mm wrench for the balance belt idlers, and a two-pin spanner wrench that you can make yourself, ala this link:



http://www.968forums.com/topic/12161-<acronym title='dual mass flywheel'>DMF</acronym>-causes-a-shakevibration/page__view__findpost__p__126170



You might have to grind the 27mm wrench down a little thinner, but that's easy.



Update: It's amazing that in this day and age, a forum software can't even insert a link to *itself*.

Partial Post: Please Login or Register to read the full post.

[flash]

odd - i have no problem adding a link to itself. i tried it and it worked fine. i just clicked the link button, pasted the url, and bingo!

Partial Post: Please Login or Register to read the full post.

[astroede]

So is it possible to set the belt tensions properly without the special Porsche tool? Sorry if this is answered somewhere else, but I couldn't find it, and it appears that the belt replacement DIY isn't done yet.

Partial Post: Please Login or Register to read the full post.

[flash]

yes, it's possible. it won't likely happen the first time you do it though.



no, the DIY is not done. now i have an even bigger challenge, as the system on which i could edit the footage is about to die.

Partial Post: Please Login or Register to read the full post.

[Cloud9...68]

The key is having the time, which means the car can't be a daily driver. There are a few DIYs out there, although they are somewhat incomplete. I would recommend diving in, and stopping to post questions on the forum at any step where you have the slightest hint of a hesitation, or where you hear a small voice telling you, "This doesn't seem right." Rest assured that we will answer promptly.

Partial Post: Please Login or Register to read the full post.

[astroede]

Thanks, greatly appreciate that. Have you seen this German video (click cc for English subtitles) for 944S2, replacing water pump and shaft seals? http://www.youtube.com/watch?v=o1P0n1DXMto Note he makes some of his tools, and there is a bit of German humor thrown in. I assume this is very similar process to 968, although he goes a bit further than I plan to go. Note his method for checking the balancer belt tension. He seems to know what he is doing...what do you think?

Partial Post: Please Login or Register to read the full post.

[tamathumper]

The tensioning tip comes at 19:10 as far as I can tell?

Partial Post: Please Login or Register to read the full post.

[astroede]

Yes, he says that the belt is moderate tension, and he demonstrates that he can twist it about 135 degrees.

Partial Post: Please Login or Register to read the full post.