Radiator Installation

Overview

This procedure outlines the steps to install a radiator in your Porsche 944 S2 with a 3.0L engine. The radiator is essential for cooling the engine by circulating coolant, and proper installation ensures optimal performance and prevents overheating. This guide helps you install a new or repaired radiator correctly, keeping your cooling system in top condition.

Pink and blue text represents links to additional resources, tools, parts, and partner websites.

Tools Required

• 10mm (3/8 inch) socket and ratchet
• Flat tip screwdriver

Parts Required

• Radiator (if replacing), 944 106 031 03
• Rubber mounting plugs (if damaged), 999 703 147 40

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Coolant System Draining, Filling, and Venting

Step-by-Step Procedure

Step 1: Install the Radiator (Porsche 944 S2 Specific)

1. Ensure the rubber mounting plugs (999 703 147 40) are installed in the bottom radiator cross-member. Replace them if damaged.
2. From underneath the vehicle, lift the radiator (944 106 031 03) into place, aligning the bottom with the rubber mounts and the top with the upper cross-member.
3. Secure the radiator by tightening the jam nuts on the retaining bolts on the upper cross-member. Tighten gently to 20 Nm (15 ft-lbs) to avoid cracking the radiator.

Step 2: Reassemble the Cooling System

4. Reconnect the thermofan switch plug to the radiator.
5. Install the cooling fan assembly by positioning it in place, securing the three bottom bolts, then the three upper bolts using a 10mm (3/8 inch) socket and ratchet. Tighten to 10 Nm (7 ft-lbs).
6. Reconnect all coolant hoses to the radiator, positioning the clamps as noted during removal to avoid interference, and tighten them with a flat tip screwdriver.

Step 3: Finalize the Installation

7. Follow this link to ensure this step – Coolant System Draining, Filling, and Venting – of the process is followed accurately. Fill and vent the cooling system with the correct coolant mixture.

Post Procedure Checklist

• Check for leaks around the radiator hoses and connections after filling the coolant system.
• Start the engine and let it idle for 5-10 minutes, watching the temperature gauge to ensure it stabilizes normally.
• Verify the cooling fans turn on when the engine reaches operating temperature.
• Inspect the fan assembly and radiator mounts to ensure they’re secure and not vibrating excessively.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube