Carrera 4S Cabriolet Coolant Expansion tank replacement DIY

[Wayne Wright]

2001 C4S Cabriolet Expansion tank replacement

 

There are many examples of replacing the expansion tank on a 996, but most that I came across  are in regards to a 1999 Coupe, which has a few subtle engine differences. I was afraid I was going to have to disconnect the big coolant tube and drain the system. Here's the details on the C4S Cabrio.

 

The basic task of removing the expansion tank does transfer over to the C4S Cabrio.

 

Differences:

The two fittings on the fuel rail will need to be disconnected, these are in the way of the lower hose connection on the tank

 

Fuel filter attached to the expansion tank, disconnect it at the quick disconnect at the top as well as at the fuel rail. Once you loosen the clamp holding it on, the filter and attached hoses will come out as an assembly

 

Fuel filter cradle/mount needs to come off the expansion tank before you pull the tank out

 

Fuel rail fitting: there is one more fitting on the fuel rail that will need to be disconnected

 

Yes, you still need to lower the engine

 

The last is the bracket that the clamp for the smog pump hose attaches to. It's a 10mm bolt that connects that one corner of the intake. Its an L shaped bracket with one hole in it. It is blocking the same lower tube on the expansion tank.

 

Not necessarily C4S in particular, but an issue I ran in to. I did need pull off the black, fingered, tank bracket as the tabs on the new tank were bent down just enough to not allow the new tank to slide in. I was able to gently pry each tab up enough to get it to slide into the bracket (while it was out of the car). I used a heat gun on low heat to soften the tabs enough that they bent up enough to allow the tank to slide in (with resistance) after reinstalling the bracket. Probably a manufacturing defect. 

 

I'm sure this will happen again, I'll get some pictures next time.