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 10 Oil Cooler housing removal? (Read 2189 times)
RedlightChallenger
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Oil Cooler housing removal?
Jun 1st, 2011 at 1:15pm
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I have a 1985 Porsche 944 with about 144,000 miles on it. About a month ago, I noticed a huge cloud of white smoke exiting the exhaust pipe. I immediately thought it was a blown head gasket, because there was also water in the oil. After changing the head gasket, I ran it for about 5 minutes, ran good, then removed the oil filter, just to find the oil in it to be latte colored and full of coolant. After some research, I discovered it could be the oil cooler housing and went to work removing the oil. However when I drained the oil it looked pristine and perfect, and the water was the same; entirely clear. ???? When I set to work removing the housing, after pulling off the fuel rail, cam, and exhaust manifolds, I am wondering how I am going to remove the oil cooler housing? Do you have to pull the engine in order to do it?  If you know anything about this please help me.
  
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River
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Re: Oil Cooler housing removal?
Reply #1 - Jun 1st, 2011 at 5:33pm
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The man deserves an award of some sorts for his work on this site.

Porsche should give him a car. Wink
  
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RedlightChallenger
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Re: Oil Cooler housing removal?
Reply #2 - Jun 1st, 2011 at 6:46pm
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Thanks for the info! This site is much more descriptive than the Haynes manual. This really helps. That guy does deserve a free car.
  
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River
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Re: Oil Cooler housing removal?
Reply #3 - Jun 1st, 2011 at 8:12pm
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I got the Haynes manual, I use it rarely. There's so many videos, this site (especially this one), and Clarks that we're set on knowledge bases write ups.

Can't mention it on the site but if you "hunt" for the shop manuals online you can find them. There is a guy selling a dvd version in Seattle on Seattle Craigslist. Or you can hunt down the books (around $200-$300).

Clarks is just awesome. Wink
  
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IAN - 944ONLINE
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Re: Oil Cooler housing removal?
Reply #4 - Jun 2nd, 2011 at 11:30am
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we also have this " how to " in the tech section -
along with loads more stuff you SHOULD do


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e mail&&ian@944online.com&&phone&&toll free in the USA 1 866 944 7883&&outside the USA&&1 954 968 3766&&FAX -1 954 968 3798
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bastafari
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Re: Oil Cooler housing removal?
Reply #5 - Jun 2nd, 2011 at 12:45pm
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There are 4 13mm bolts holding it on. Kind of hard to reach but it can be done. Clarkes says to remove the manifold but I just removed my power steering and sway bar out of the way instead and was able to remove and install it back. Admittedly the clarkes method is easier but then you'll need new exhaust gaskets.
  
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darrellsp
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Re: Oil Cooler housing removal?
Reply #6 - Jun 2nd, 2011 at 1:33pm
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When I did my Oil Cooler I didn't remove the exhaust manifold either. It's tight quarters in there but it can be done.

I remember loosening and tightening the oil cooler alignment tool many times while I was tightening the four bolts to the oil cooler to be sure it had free play and wasn't binding. It took a while before it finally was seated right.

The tech section here really helped me too.
  

89 944 n/a
Baltimore Maryland
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RedlightChallenger
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Re: Oil Cooler housing removal?
Reply #7 - Jun 2nd, 2011 at 2:05pm
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My car had the milkshake oil, so I changed the head gasket. changed the oil, and after I ran it for about 4 minutes and pulled off the filter it was milkshake again. I left the car alone for a week and drained the oil, but the oil looked brand new then, no milkshake whatsoever ??? Does anyone know what would cause this? milkshake only in the filter?
  
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bastafari
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Re: Oil Cooler housing removal?
Reply #8 - Jun 2nd, 2011 at 2:10pm
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What does the coolant look like? Milkshake?
  
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RedlightChallenger
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Re: Oil Cooler housing removal?
Reply #9 - Jun 5th, 2011 at 10:48pm
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The coolant is also perfect, no oil in it whatsoever. It is all very confusing
  
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bastafari
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Re: Oil Cooler housing removal?
Reply #10 - Jun 6th, 2011 at 9:52am
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Well I don't know about what the oil in the filter should look like but generally you want to go by the coolant in the expansion tank ( milkshake ) or the oil from being drained. I pour my oil in an empty milk gallon to see. Coolant or water will separate at the top. So maybe it was your head gasket. Is the car overheating?
  
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RedlightChallenger
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Re: Oil Cooler housing removal?
Reply #11 - Jun 12th, 2011 at 7:55pm
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nope. never overheated, but I changed the oil cooler gaskets and it seems to be clear now.
  
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IAN - 944ONLINE
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Re: Oil Cooler housing removal?
Reply #12 - Jun 16th, 2011 at 1:04pm
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PROBABLY JUST RESIDUAL OIL in all those small oil gallies that don't easilly drain
  

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River
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Re: Oil Cooler housing removal?
Reply #13 - Jun 16th, 2011 at 10:53pm
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+1 what Ian said.

I'd run a serious engine flush and a coolant flush.

I forsee...flushing in your future Wink
  
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Sy944
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Re: Oil Cooler housing removal?
Reply #14 - Aug 10th, 2015 at 8:13am
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Hi All,

I'm digging up this thread as I recently did my oil cooler seals and found forum posts like this hugely helpful - hopefully a few points might assist anyone else doing the same job:

- you don't need to remove the exhaust manifolds, but I can see how it would change an extremely awkward job into a mere slightly fiddly task.  I decided not to as the exhaust manifolds don't look like they've ever been off my car ((1987 2.5 NA, UK spec) lots of flaky surface rust) and didn't fancy rounding off any of the studs or nuts.  If I had a 2nd car and a workshop full of helicoils I might've been tempted. 
- I didn't use the crowfoot adapter or 32mm spanner (that some people have talked about) - no idea which models these are recommended for but my oil pressure sender came off with a normal 24mm open-ended spanner...
- I purchased a 3/8" UJ to enable access the main oil cooler bolts.  Frankly, without this I think this job would've been truly impossible (especially removal of the upper-front oil cooler housing bolt, where even with the UJ and several exension bars was still very difficult
- you have to remove the heatshield from the oil cooler to get to the upper mounting bolts.  It's easy enough to remove the securing bolts from under the car with the right socket set, however I was unable to remove the heatshield itself from the car, due to lack of clearance with the exhaust manifolds, wheel-arch etc... you have to slide the heatshield forward to access the rear oil-cooler mounting bolt, and vice versa.  When it's off might be a good time to wire brush off any loose rust / debris from the underside of the manifolds, so that as little as possible falls into the oil-cooler area when you're trying to reassemble it cleanly.
- I found it very difficult remove the oil cooler housing out the opening below in its 'normal' orientation - I had to almost twist it round 180° to get it free of the car in the end - even after removing the anti-roll bar and hanging the PAS pump out the way, I still had to remove the mounting bolts for the annoying PAS line that runs almost diagonally across the opening; the addional 5mm-6mm of play this provided was just enough to remove the cooler from the car.

Maybe this makes it sound worse than it was, but as long as you're prepared for one of those days where you feel you're performing a relatively difficult task, whilst your're working through a letterbox, it's definitely possible.  500 miles on and my oil leaks have disappe
  
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