I shouldn't have posted. Found a puddle today, just after getting the car back from being pinned...

 

Well, things are underway. I received my 3 radiators today from jrp and I'm just waiting for my coolant flushing system due on Monday. I'm thinking of a diy since there doesn't seem to be one out there.
Tom

 

There really isnt one. Theres quite a few on front bumper removal. After that everything is self explanatory anyways.

 

I realize this is for a 996 but the steps should be close to identical.
Just need to verify the correct plug to pull under the motor.

See below:
http://www.pedrosgarage.com/Site_3/F...nt_System.html

 

Hi
OK bumper is off, hoses removed, center rad removed all simple up to here. Now the left and right rad is another question.
How do you remove them? Not at all obvious. I have removed the air conditioning condensors, and removed the colored bolts from the sides but I cannot seem to get the rad to budge. There is a bracket behind it all and yes it could be removed but this is a lot of effort. I would need to remove several other hoses and it doesn't make sense. I have not been able to find a diy for this on the 997. Yes there are for 996 but this is very different.
Any ideas?

 

Figured out how to remove the left and right rads. Not obvious at all and you need a very very low profile torx 25 bit. One in a 1/4" ratchet is too big. I'll post a picture when I'm done.
For now another issue has arisen. I worry about the quality control of the CSF rads for the 997.1 Turbo. First, on one rad, the position of the screws for the air conditioning condenser were off. I had to elongate the plastic condenser mounting brackets.
Second, all clips were missing from one rad. It was obvious when I opened it that someone had been into the package and removed them since the plastic was opened just around the clip.
I tried the original clips and it does not seem that they fit just right. In fact I am wondering if I am now stuck with the original problem as mentioned in the 996 threads. Who's to say when these radiators were made and shipped to Canada?
So my car is in pieces, I'm waiting for the clips, and I don't know if I have old stock.
A bit of a mess no? Especially when you consider I'm out $2600+ for the rads. How can I tell which stock are these?

 

Never mind. I DID receive the old stock. Apparently, CSF never informed their Canadian distributer (JRP) and the stock I took delivery was delivered prior to JRP correcting the problem.
So the EXACT thing I was worried about happened. So now IO'm sitting on questionable stock.

 

You did not receive old stock of the radiator. Just the clips were missing from the box.

The reason that the plastic was opened around the connection was to inspect it to make sure that it was correct.

The clips are being overnighted to you as we discussed over the phone. Please consult and give the vendor a chance to take care and discuss any issues before mentioning information on the forum which may be inaccurate.

I responded to your dealer and your email within minutes of getting your message. The problem is being taken care of, and you will get clips tomorrow.

Thank you.

 

Yes, the clips are on their way. As it turns out, there was not a specific design issue in the past just a few rads that were out of spec as a result of a cnc error.
In any case, the manager of csf assured me that even if there is an issue a new radiator would be on its way in a day. Great support and things should be just fine.

 

I had the same issue with the AC condenser holes not lining up, but as you did, enlarging the holes a little solved the problem.

 

The issue now is refilling the system. I bought an airlift vacuum flusher and as I try to put a vacuum it goes to 15 and then immediately drops back down to 10 as if a valve has opened up and let air into the system.I can't seem to ever get the vacuum to 25.
I did try filling it anyways and it is short by two liters or so.
How did you fill?

 

I didnt use a vac at all. My method was i made sure to prefill them as much as possible during the install, then just old school filled it up, drove it around, topped off, drove again. Did this a few times during the week whenever i got home from work. Its been good ever since. I dont notice much of a difference from before, maybe the needle is slightly lower, meaning its working.

 

Well it all looks good. The engine was started, and antifreeze added as it warmed up. Eventually it would take no more and then as the temperature reached operating, the hoses filled, level went down and then I closed the bleeder. Now all looks OK, no apparent leaks, no antifreeze smell !finally!
After it cools co pletely I'll top off the level, and I should be good to put the bumper back.
Thanks to all that helped. I'll do a small summery tomorrow for the trickier points.
Tom

 

Great, now after you get that bumper back on, you can get yourself a nice cold beer for a job well done and enjoy your new interfoolers