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YOUR RESEARCH2000 996 New Mahle Expansion Tank Leaking!
Leading reported evidence
Replace jeep will push any coolant
Performed · outcome unconfirmed
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My death machine v8 swapped jeep will push any coolant to the overflow once it gets
Leading evidence: 'Replace jeep will push any coolant' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Fill half way between' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Suggestion
fill half way between, on mine the bleeder will burp coolant if filled to the Max..
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Suggestion
Rather than weld that bracket in,,,, I would make it have longer "feet" and use chassis bond to glue it in place, the stuff is what holds almost all pickup bed side skins on and many other body pieces.
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I replaced the original expansion tank last May. It was replaced with a Mahle part. My indy has pointed out that the new one is leaking at the top near the pressure relief valve. $900 for a new Porsche part and $500 to install. Yikes!
Anyone have experience with this or with Mahle warranty. During todays service 1 litre of coolant was required to top off the tank.
The 2000 996 uses:
996-106-147-56-OEM.
Questions for the forum:
1) Can I live with this and just keep topping off the coolant or am I flirting with disaster?
2) Any way to repair the valve part of the tank?
3) Anybody know what the Mahle warranty is?
Thank you,
You want the blue cap, it is he later version. If the tank leaks, replace it with a genuine Porsche tank. None of the aftermarket tanks seem to hold up well. You can use the 996.2 version in a 996.1. It will fit and is much less expensive. I buy all mine from Porsche Marin in CA. IIRC, I paid about $175 for the last three I bought.
Mark
Mahle warranties are 1 year, unfortunately. FWIW, on any of my long-term keeper cars I shop from FCP. They are usually a little bit more on price, but have a lifetime warranty on everything they sell. If you switch to the 996.2 tank, be sure to research it. I recall reading a post documenting the swap and it was doable, but I think I recall it was a bit tricky getting it to fit. That could have been related to a C4 vs. C2. Its been several years since I read the post, but definitely research it before going that route.
Looks like its the cap that is the problem. Check the part number on the cap. Needs to end in .02 or .04 Not sure which is the right one, but in any case, I would try before buying the Porsche part.
I put the newer, larger expansion tank; the Porsche branded one in my 2000 C4 Cab. It is a little more work, but it will fit. And it is available for less than $200 from Pelican. I will post some pictures.
I did this myself and had the engine out when I did it, but it could be done with the engine in, just lowered some which you will want to do even with the smaller tank. Now a mechanic may not want to do this, but the Porsche version of the older, smaller tank is now over $800.
Something else to keep an eye on, the tank is marked min-max, DONT fill to max,
fill half way between, on mine the bleeder will burp coolant if filled to the Max..
And +1 looks like you do have the old cap it should be blue...
It will also burp coolant if there are any bubbles in the system, vacuum lift is golden.
In general,, I've always found cooling systems kinda find their sweet spot,
My death machine v8 swapped jeep will push any coolant to the overflow once it gets
filled more and about 1 inch above the tubes in the radiator. It just wants some space in the upper tank.
Once it pushes it our, it stays rock solid after that..
Having done this job three times on my 2000 Cab, I can't imagine how you would fit the larger MK-II tank in there. Even the smaller tank is a nightmare to do.
So here is my question:
Upon further review, while a small amount of coolant did escape near the bleeder valve while my car was in for routine service - I cleaned it all up and drove the car three times. There is no visible coolant leak anywhere near the expansion tank.
The Indy added 1 liter of coolant so now I�m thinking they over filled it.
1) Is this a reasonable assumption?
2) Is loss of 1 liter of coolant over a 1 year period to be expected? Or is it indicative of a leak some where else in the system?
I work with a very reputable indy. But I�m miffed that he�s telling me to replace a $950 tank that is only 1 year old!
Appreciate your feedback.
U shouldnt be loosing any coolant. The tank may be cracked and leaking only when pressurized so u dont see it. This is a common issue.
Dont be miffed, i know its hard to believe but the only tanks that dont leak or crack after a short period of time r the porsche tanks. We cant seem to find the actual porsche supplier for this part so the folks here just spend the money on the dealer part, so they dont have to do the job twice. Do a search as there r probably 50 threads in the last 2-3 yrs about it.
Here is a picture of the ol, smaller tank in place.
Here is a picture of the new style, larger tank in place.
This is a picture of the additional mount toward the rear of the newer tank. This is on the body above the tank from the factory. This picture is actually a bracket that another owner sourced from another car and had welded in place, you can't buy just the bracket. I did not put in the bracket, I just put the foam on the tube below the tank to keep it from vibrating against the tube. The tank sits very firmly.
Now I did do this when the engine was out of the car which made is easier, but it could be done with the engine in the car. As you know even with the smaller tank the replacement is a pain to do. and with either style I would lower the engine as far as possible with the engine mounts and a jack. But it certainly can be done and the price difference for the Porsche branded tanks covers a lot of labor!!
Guarantee-schmarantee. This job is a major PITA. You want to do it once, not every year or so because it's a lot cheaper and has a life-time warranty. Bite the bullet and buy a Genuine Porsche coolant tank. I'm talking from direct experience. And be careful where you buy it. I paid for a Genuine Porsche tank from AutoHausAZ but received a third party tank that came with a black cap. A real Porsche tank doesn't come with a cap. Buy the blue Porsche cap.
If it makes you feel better, the BMW cars of the same vintage have the same issues and the same fix, ONLY use the factory part.
On the BMW its another 1000 dollars to fix , cause once your started its a BIG job. Needs done about every 85K ... (2000 to current BMW's.. )
A few years ago I openly asked on a similar thread why someone hasn't created a
billet aluminum equivalent.
If I recall correct,
Porschetech3
considered it.
The non-genuine Porsche tank I purchased 10 years ago leaked after 50ish days at a seam. I purchased a
Harbour Freight Plastic Welder
, intending on just melting those seam together again, but on the advice on my indy mechanic, just forked over the $$ for a genuine. 10+ years later, and a full refill two years ago (after an engine rebuild), still holding fine. Decisions, decisions
at a seam (video)
Rather than weld that bracket in,,,, I would make it have longer "feet" and use chassis bond to glue it in place, the stuff is what holds almost all pickup bed side skins on and many other body pieces.
That tank doesn't weigh much...
