Radiator Installation – 2.5L NA

Overview

This guide details the steps to install the radiator on all Porsche 944 variants with an 8-valve engine, covering pre-1985.5 (1983–1985.5) and 1985.5 onwards (1985.5–1988) models. Proper installation of the radiator is essential for maintaining the cooling system and preventing engine overheating. Follow these steps carefully to ensure secure connections and avoid damaging components.

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

Tools Required

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

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

1. Ensure the rubber mounting plugs are installed in the lower radiator cross-member to support the radiator.
2. From underneath the vehicle, lift the radiator 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 upper cross-member retaining bolts using a 10mm (3/8 inch) socket or wrench. Tighten gently to avoid cracking the radiator.

For models with automatic transmissions (Pre-85.5 and 85.5 Onwards):
Reconnect the transmission fluid hoses to the radiator, ensuring secure connections.

4. Reconnect the thermofan switch electrical connector to the radiator.

Step 2: Reinstall the Cooling Fan Assembly

5. Position the cooling fan assembly in the vehicle and secure it with the three bottom bolts using a 10mm (3/8 inch) socket and ratchet.
6. Reconnect the fan electrical connectors.
7. In the engine compartment, secure the fan assembly to the upper radiator support with the three bolts using a 10mm (3/8 inch) socket and ratchet.

Step 3: Reconnect Hoses and Refill the System

8. Reconnect all coolant hoses to the radiator, ensuring the hose clamps are positioned in their original orientation to avoid interference with other components. Tighten the clamps securely using a flat-tip screwdriver.
9. Follow this link to ensure this step – Coolant System Draining, Filling, and Venting – of the process is followed accurately to fill and vent the cooling system.

Post Procedure Checklist

• Check all coolant hose connections for leaks after refilling the system.
• Verify that hose clamps are oriented correctly and do not interfere with other components.
• Ensure the cooling fan assembly operates correctly by running the vehicle and checking fan activation.
• Confirm the radiator is securely seated in the rubber mounts and the upper cross-member bolts are tightened appropriately.
• Check that all tools and debris are removed from the engine compartment and under the vehicle.
• For models with automatic transmissions, verify the transmission fluid hoses are securely connected and free of leaks.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube