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I was able to get the left drivers side fan to spin slowly by applying 12 volts continuously with a 10 amp battery charger connected, and spinning the fan blades by hand, but it turns very slowly, stops often, and there is some play in the bearing. Wondering if I can get it out without too much work, if it can be rebuilt.
After fixing a coolant leak in my '05 Boxster S, (see my thread on replacing the Coolant Guide Housing), I discovered that both of the radiator fans had stopped working. The passenger right side was a quick fix- there was a small piece of gravel between the fan blades and the housing. Spinning the fan by hand got it going again, and it runs full speed with the AC on. I understand that the 987/997 models have an intelligent fan control unit which varies the fan speed based on demand, instead of the two speed feature using a ballast resistor in the earlier 986/996 models. The driver's side, however, probably has been inoperative for some time. I tried applying 12 volts to the fan connection, and nothing. I want to remove the assembly, and replace it or fix the motor, but I'm trying to figure out if it can be removed without the radiator. It looks like it should come out with just the wheel liner removed. Any suggestions, or a procedure anywhere for removing just the fan with motor? the 5000 page factory workshop manual doesn't cover it, I've seen Wayne Dempsey's procedure for the 986/996 fan, and Pedro's 986 procedure, but the 986/996 fan assemblies are significantly different, so I'm looking for a procedure for removing and replacing the 987/997 left drivers side fan. There are plenty of fans for sale (in the $200-$500 range!), but can't find a procedure. Any advice would be appreciated. Gary
Sorry for not posting for a while. Anyway, the coolant guide housing was replaced, and there is no coolant loss now, opening the bleed valve seems to have removed any air bubbles, and the car runs great. On a somewhat related topic, I just discovered that both of the radiator fans had stopped working. The passenger right side was a quick fix- there was a small piece of gravel between the fan blades and the housing. Spinning the fan got it going again, and it goes on full speed with the AC. I understand that the 987/997 models have a fan control unit which varies the fan speed instead of the two speed feature using a resistor in the earlier 986/996 models. The driver's side, however, probably has been inoperative for some time. I tried applying 12 volts to the fan connection, and nothing. I want to remove it, and replace it or fix the motor, but I'm trying to figure out if it can be removed without the radiator. It looks like it should come out with just the liner removed. Any suggestions, or a procedure anywhere for removing just the fan with motor? the 5000 page factory workshop manual doesn't cover it, I've seen Wayne Dempsey's procedure for the 986/996 fan, and Pedro's 986 procedure, but the 986/996 fans are significantly different, so I'm looking for a procedure for removing and replacing the 987/997 fan. There are plenty of fans for sale, but can't find a procedure.
Progress! I removed the front engine mount to be able to remove the Water Guide Housing. Access to the top engine mount bolts is very tight, so I used a 15mm crow's foot on a 3/8" breaker bar to break them loose from above. The mount is slotted for those top bolts, and the mount slips down with the top bolts in place, but you have to remove the studs for the lower mount to do so. Also had to remove the oil pressure relief valve to provide clearance to remove the Water Guide Housing. The seam is broken on the plastic housing about 3 inches long. I filled it with water, and it drips out. This part is made in France like the water pump that fails often. Finally, I can start assembling. Probably need a o-ring for the Henn coupling I opened. Anyone have a recommendation for an affordable cooling system coolant pressure tester available in the U.S.? I was thinking about modifying a spare Boxster coolant cap to adapt to a tester. Also, once the coolant is in, is opening the bleeder valve and running the engine enough to bleed the system? I know there are systems to do bleeding, but I'm doing this on a budget. Thanks again for your advice on the mount, RFM Flanders!
Flanders- Thanks very much for your reply regarding supporting the engine, and removing the front central engine mount. That's encouraging. I'll try it as soon as I have a few hours, and report back. Regards, Gary
At first I thought the water pump was leaking, but with careful examination, discovered the plastic "Water Guide Housing" (P/N 987-106-508-04) used to route coolant from the front of the engine to the front radiators, sprung a rather large leak at the mold seam on the bottom of the part near where it makes a 90 degree bend and joins the "Henn" fitting on the large rubber hose. I removed the 9 screws attaching the housing to the engine, and have a new replacement part, but can't figure out how to get it out, because it snakes around the front engine mount, which looks very difficult to remove. It looks like it would remove straight down if the mount wasn't in the way, and maybe it could be removed and replaced from the top side, but that's very tight with pulleys. There must be a way to get this part out without removing the engine? This is not a commonly replaced part- the parts guy at the dealer said he has only sold one of these in several years, and I see no mention of replacing it in the 5000 page factory workshop manual or anywhere on the internet. Does anyone have experience with replacing this part with the engine in the car? I would appreciate any insight, and would even pay for a solution. I would like to get the car back on the road. Summer is very short here in Minnesota. Gary
Does anyone know where I can get a Porsche factory workshop repair manual on CD for the 997.2 series?