DIY waterpump , serp belt , etc.

[por911]

Here's a pic of the pump after installation. One can see, the rear carpet and metal access panel behind the seats needed to be removed. Make sure to have a large drain pan handy, as the 986 holds alot of coolant. You might want to actually put the drain plug back in just to empty the pan a few times. Part #'s for a base 01(2.7):

1)996-106-011-55, waterpump

2)996-106-340-54, waterpump housing gasket

3)996-102-151-66, serp belt(optibelt)

Have a decent pair of small metal snips, as the gasket comes with the oil pump housing gasket attached as well. This needs to be trimmed off. This is also true of the old gasket. There is little, if any room to work in there, so patience is helpful here. I also replaced the deflector and tensioner rollers while in there. It should be mentioned that these don't like to be retensioned with a new belt installed after 60k. They usually start making noise not too long afterwards.

Note on installing new rollers, that bolt for the upper roller just makes it out with perfect or new driveline mounts. If your 986 mounts have collapsed some, expect issues getting this bolt out.

-Torque spec:

waterpump , 7ft lbs

thermostat housing , 7.5ft lbs

I'll post more as the project moves along. The pic shows new waterpump, serp belt, deflector roller, and tensioner roller installed.

Regards

[por911]

Here's a pic with the old pump removed and the old gasket trimmed. Its a good idea here to clean off everything(excess coolant, gasket surface, etc.). Some find it helpful to scribe an outline on of the new gasket on a piece of card board. As your removing the bolts from the waterpump, place them in the appropriate location on the outline of the pump on the card board. There are 2 bolts in the waterpump hardware that are longer then the others. Its helpful not to mix the locations up.

[por911]

Here's a pic of the t-stat and housing installed. Part #'s for a base 01:

1)996-106-326-50, thermostat housing gasket

2)996-106-125-53, thermostat (regulator)

3)996-106-121-53, thermostat housing (waterpump outlet tube)

Torque spec for housing bolts, 7.5ft lbs (just incase people missed it in previous post)

Due caution should be taken here. I found alot of left over residue from the previous gasket which took alot of work to remove without marring the gasket mating surface. If you have the old spring type clamps, it might be a good time to upgrade them to the more dependable screw type. The factory ones are made by Norma. I find ABA clamps are quite reliable as well. Take due caution in installing the new t-stat as to keep the arms relatively level when turning them into locking postion to the housing. Porsche makes a special tool for this #9627, but its possible to install it without if your exceedingly mindful. As always, the job is much easier with the proper tools.

[por911]

Here's a pic of the new waterpump and trimmed gasket.

[por911]

What a bad waterpump looks like. Notice the dried coolant that has been leaking. If your under your 986 and see this, its coming time to think about a waterpump replacement.