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Water Pump Replacement


See Robin's DIY at his site: 996 Water pump replacement/ Alternate PDF file (if link does not work) 996_water_pump_replacement_procedure.pdf 996_water_pump_replacement_procedure.pdf

 

  • Upvote 1

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loren, i need your help!!!

i followed all the diy instruction on removing the water pump. i got all the screws off the water pump, but my problem is that it wont come out, i tried taking it out trough the top and theres not enough clearance, and i tried the bottom and its the same problem. Do you know if the water pump comes out the top or the bottom? and if theres any specific angle or something else i can do to take out the pump? thanks in advance.

03 carrera cab, 6 spd

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yes. I loosend the bracket, if try to take it out from the top it hits the bracket and the same happens in the bottom, but in the bottom it also hits a small water hose that's made out of metal . Could it be that I have the car on jack stands intead of the ground? Or should I completely remove the bolts from the bracket

I finally took it out. Had to loosen a few other hoses but finally got thanks

Edited by mclakers

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yes. I loosend the bracket, if try to take it out from the top it hits the bracket and the same happens in the bottom, but in the bottom it also hits a small water hose that's made out of metal . Could it be that I have the car on jack stands intead of the ground? Or should I completely remove the bolts from the bracket

I finally took it out. Had to loosen a few other hoses but finally got thanks

I just finished doing this myself, had the same problem and thought I'd clarify a couple of points for future readers. The pump comes out the bottom. I had the car up on jack stands with a jack supporting the engine. I completely removed the two bolts from the rear engine support but left the two nuts just barely on. You could probably completely remove the nuts too, it just isn't necessary. The two ends of the support are attached to the two rear motor mounts so the thing isn't going to go anywhere. With the bolts removed and the nuts loose you want to pull the bottom of the support towards the rear of the car to give yourself a little more room to get the pump out. If you pull and nothing happens, you may need to adjust the jack to raise or lower the engine slightly; it shouldn't take much force to move the support. Separate the pump from the engine (gently pulling on the pulley should be enough) and make sure that the metal gasket is not stuck to pump. Once it's free from the engine you'll probably have to rotate the water pump a bit to get it out. If it doesn't rotate then part of the gasket is probably stuck to the pump, most likely at one of the two locating pins. It takes a bit of wiggling and the pump will want to get hung up on one of the metal coolant lines, but you should be able to work the pump out past the hoses and rear engine support. I actually removed two of the mounting clips for the metal coolant line on the left side of the engine so I could push the silly thing out of the way a little more.

Not the easiest procedure in the world but far less of a headache than installing the Techquipment roll bar!

  • Upvote 1

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What I do not get is the use of a metal gasket.

Here are some Boxster pumps, same as a 996.

Third pic is from FrayAdjacent.

post-4-1220657416_thumb.jpg

post-4-1220657697_thumb.jpg

post-4-1220657924_thumb.jpg

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Hi,

This was a great DIY. I just had to add that you have to take out the pump from above. Also I got a good deal on a heavy duty pump with metal impeller for $106 on Ebay and it's been working great.

Kristian

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I can't open the link to the DIY. Does anybody know if it has been moved, or if it is posted to a different location?

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I can't open the link to the DIY. Does anybody know if it has been moved, or if it is posted to a different location?

I added a PDF copy to the first post.

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My pump gave away. Dealer wanted to charge me $1,300. I bought it on sunset, $187 plus shipping, and followed instructions. Spent sunday morning and new pump is installed and working. Thanks Loren and all :)

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If you notice, all the water pumps come with a thermostat housing gasket as well. It's not only a good idea to go ahead and replace the thermostat when you do the water pump, but is MUCH easier to slide the pump out if you remove the thermostat housing and can pull that hose out of the way.

By the way, NAPA has started carrying remanufactured 996/986 lifetime warranty water pumps for $144 with an $11 core charge.

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So that NAPA water pump I was so excited about is making grinding noises after only six months. Looks like I'm swapping it again this weekend. I'll try to make a video this time.

If you notice, all the water pumps come with a thermostat housing gasket as well. It's not only a good idea to go ahead and replace the thermostat when you do the water pump, but is MUCH easier to slide the pump out if you remove the thermostat housing and can pull that hose out of the way.

By the way, NAPA has started carrying remanufactured 996/986 lifetime warranty water pumps for $144 with an $11 core charge.

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Here's the video. Sorry for the shakiness and poor audio. I found my old 24-bit PCI soundcard isn't supported in Windows 7, and I've yet to invest in a new USB recording system.

I only make these when something on my car breaks, so if anyone else in the Houston area wants to collaborate, I'll be happy to assist and film your next project.

Edited by Loren
Fixed YouTube link
  • Upvote 4

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Here's the video. Sorry for the shakiness and poor audio. I found my old 24-bit PCI soundcard isn't supported in Windows 7, and I've yet to invest in a new USB recording system.

I only make these when something on my car breaks, so if anyone else in the Houston area wants to collaborate, I'll be happy to assist and film your next project.

Excellent DIY video ...Thanks

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I wish I would have done this job myself, after watching the video, it looks doable. My problem is my coolant was coming out in a stream the diameter of a pencil and I pulled into my local independent german car shop. For some reason the water pump gasket is connected to the oil pump gasket and I think my awesome mechanic damaged the oil pump housing gasket. The mechanic installed new water pump and now the oil pump housing is leaking coolant, WTF? Has this happened to anybody else? He wants to charge me at least two more hours to fix the leak, **** it is hard to find a good mechanic.

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I recently used this thread to replace the water pump and thermostat on my car; thanks to everyone who posted tips, diagrams, instructions, you-tube videos, and parts pricing.

Now on to the next project, replacing the 'crankcase breather hose' part # 996-107-147 (or 155)-55; anyone have any experience replacing it?

Tim

Las Vegas

'03 996 C2 cabriolet w/manual gearbox.

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Does anyone have a list of the torque specs for all the differant bolts in this job?

Drain plug - 7.5 ftlb. (with new sealing ring)

Water pump - 7.5 ftlb.

Engine carrier - 22 ftlb.

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It shows $269.99. A little off from $135, now. High price!

After reading that great DIY, I'm inspired to try this. I found an aftermarket water pump on Automotion for only $135:

http://www.automotio...93&dept_id=4329

Anyone have any experience with this unit? I like to save money as much as the next guy, but I'd rather not have to replace this thing again in six months.

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