Radiator Removal – 2.5L NA

Overview

This guide details the steps to remove the radiator from all Porsche 944 variants with an 8-valve engine, covering pre-1985.5 (1983–1985.5) and 1985.5 onwards (1985.5–1988) models. Removing the radiator is necessary for maintenance, repair, or replacement to ensure the cooling system functions properly. Follow these steps carefully to avoid damaging components or causing leaks.

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
• Diagonal cutters

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: Prepare the Vehicle

1. Disconnect the negative battery lead to ensure safety while working on the vehicle.
2. Follow this link to ensure this step – Coolant System Draining, Filling, and Venting – of the process is followed accurately to drain the coolant system completely.

Step 2: Remove the Cooling Fan Assembly

3. In the engine compartment, use diagonal cutters to cut any plastic retaining straps securing the fan shroud.
4. Using a 10mm (3/8 inch) socket and ratchet, remove the three bolts attaching the fan assembly to the upper radiator support.
5. From underneath the vehicle, cut any retaining straps securing the fan wiring to the fan housing using diagonal cutters.
6. Unplug the electrical connectors for the cooling fans.
7. Remove the three bolts from the bottom of the fan assembly using a 10mm (3/8 inch) socket and ratchet, then carefully remove the fan assembly from the vehicle.

Step 3: Disconnect the Radiator

8. Loosen the jam nuts on the two radiator retaining bolts located on the upper cross-member using a 10mm (3/8 inch) socket or wrench.
9. Loosen the radiator retaining bolts to release the radiator from the cross-member.
10. Unplug the thermofan switch electrical connector located on the radiator.

Note: Before removing the radiator hoses, observe the position and orientation of the hose clamps. Note their orientation for reinstallation to avoid interference with other components.

11. Disconnect all coolant hoses from the radiator using a flat-tip screwdriver to loosen the hose clamps. Have a container ready to catch any residual coolant.

For models with automatic transmissions (Pre-85.5 and 85.5 Onwards):
Disconnect the transmission fluid hoses from the radiator. Plug the hose ends and radiator fittings with suitable plugs or caps to prevent fluid loss and contamination.

Step 4: Remove the Radiator

12. From underneath the vehicle, gently push up on the bottom of the radiator to disengage it from the rubber mounts on the lower cross-member.
13. Pull the bottom of the radiator toward the rear of the vehicle to clear the mounts, then carefully lower the radiator out of the vehicle.

Post Procedure Checklist

• Ensure no residual coolant is leaking from disconnected hoses or radiator fittings.
• Verify that the orientation of hose clamps has been noted for proper reinstallation.
• Confirm the fan assembly wiring is secure and not damaged during removal.
• Check that all tools and debris are removed from the engine compartment and under the vehicle.
• For models with automatic transmissions, ensure transmission fluid hoses are plugged to prevent contamination.

Sources

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