Retrofit engine oil cooler to a 3.6 964 motor (how to w/pics)

[uwanna]

Back in '92, I stumbled onto a very low milage 964 motor and decided it needed a home in my '80SC. In perusing the motor I saw a useless power steering pump where the on engine oil cooler belonged! Back then, there were no package deal kits, so I had to backyard engineer the transplant myself. The lack of the engine oil cooler really anoyed me because although I had the fan cooled Carrera fender cooler, I knew I would need additional cooling. Ergo, I thought, lets retrofit a cooler to the engine.
That all happened 20 yrs ago and everything worked out great. Oil temp never gets above 210deg even on 95deg and above days. Recently I developed a slow drip from the oil cooler after the engine warmed up, so I was time to replace it. Here are the pics of the replacement with some notes on how I did the retrofit originally.
Firstly, the cast oil gallery holes needed to be drilled out. I took off the 964 thermostat cover plate and stuffed some rags down the "thermostat hole" to catch any metal chips when the drill broke through. Cleaned everything up and fitted four studs to mount the cooler. You also need to source and install a thermostat. You will also need to move the oil pressure sender to the plugged oil gallery near the rear of the motor.

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Next, I had to craft an oil return pipe. I used a length of steel pipe and welded on the threaded piece from the old 964 pipe, and added a piece for a hose fitting on the other end. Then I welded on a nut with the correct threads for a temp sender. This was neccesary because when you replace the 964 thermostat cover with an actual thermostat, you lose the location for the temp sender and there is no other handy place to put a sender! This seems to work quite well oil temp wise, as with the large amount of oil coursing through the system, you are getting a good average oil temp indication.







Next, the cooler needs to be modified by cutting off the oil return pipe to clear the new steel return pipe.



Although the 964 doesn't have the "tunnel" for cooling air from the fan shroud, it still receives forced air from under the shroud.



Next, test fit the cooler.



Next, install the oil gallery o-ring gaskets and bolt her on.



I then fabricated a baffle plate for the top of the cooler from some left over 964 tin.



Really a very simple process. After driving this little rocket with the 3.6 motor for 20 years trouble free with normal and acceptable oil temps, I think the cooler retrofit turned out quite well. It may look a bit crude but it sure works!

If you have any questions or need further clarification, don't hesitate to ask.

Grant

[will hung]

Cool post. Very interesting solution. I wonder if there would be a market for shrouds with the tunnel made into them to route more air to it?

[uwanna]

Originally Posted by will hung

Cool post. Very interesting solution. I wonder if there would be a market for shrouds with the tunnel made into them to route more air to it?

Will,
A forum member Billjam from AUS built his own shroud tunnel and did a very elegant engineering job on his retrofit, including relocating the oil temp sensor to the same location that was used on earlier engines. My job was 20yrs ago and I did a quick and dirty fix, but it WORKS and keeps my oil cool, even in the blistering hot Atlanta summertime. However, Billjam's efforts make me feel totally inadequate! LOL

3.6 with ITBs & MS3X into G50 Carrera – the story so far

[will hung]

I did see that thread, and my god it is some clever craftsmanship. Dang you 3.6 guys tempting me and my wallet!

[uwanna]

Originally Posted by will hung

I did see that thread, and my god it is some clever craftsmanship. Dang you 3.6 guys tempting me and my wallet!

Will,
If you know someone with a early Pcar with a 3.6 transplant, coerce him into letting you take it for a solo test drive. On second thought, better not, because then you will be obsessed till you "git er done" to your car.
Let a friend who owned an '85 Carrera take mine for a spin, and he replied "Wow, that thing pulls like a V8"
Best,
Grant

[will hung]

Originally Posted by uwanna

Will,
If you know someone with a early Pcar with a 3.6 transplant, coerce him into letting you take it for a solo test drive. On second thought, better not, because then you will be obsessed till you "git er done" to your car.
Let a friend who owned an '85 Carrera take mine for a spin, and he replied "Wow, that thing pulls like a V8"
Best,
Grant

I really don't want to do that. I have a friend with a 930. He offered to let me take it for a spin, but based on what another friends told me, I didn't. I was told that you think your 911 is fast, then you drive a 930. Then you want to throw rocks at your 911.

[uwanna]

Originally Posted by will hung

I really don't want to do that. I have a friend with a 930. He offered to let me take it for a spin, but based on what another friends told me, I didn't. I was told that you think your 911 is fast, then you drive a 930. Then you want to throw rocks at your 911.

Interestingly, the 3.6 964 motor has almost the same HP and torque ratings as the early ('76-'77) 930 Turbo Carrera, but with no turbo lag! Also you don't have a that damned extra plumbing and all the typical turbo problem areas. Not to mention the shock from the insurance quote when you mention the word TURBO.

[drmatera]

Originally Posted by uwanna

Interestingly, the 3.6 964 motor has almost the same HP and torque ratings as the early ('76-'77) 930 Turbo Carrera, but with no turbo lag! Also you don't have a that damned extra plumbing and all the typical turbo problem areas. Not to mention the shock from the insurance quote when you mention the word TURBO.

yes the hp and tq may be similar but thats were it ends.

[will hung]

Originally Posted by uwanna

Interestingly, the 3.6 964 motor has almost the same HP and torque ratings as the early ('76-'77) 930 Turbo Carrera, but with no turbo lag! Also you don't have a that damned extra plumbing and all the typical turbo problem areas. Not to mention the shock from the insurance quote when you mention the word TURBO.

It's very tempting. I've read that, all things being equal (flywheel/pressure plate and exhaust) the plastic intake 3.6's are lighter than 3.2's. Probably not much heavier than 3.0's. Mainly due to titanium being used for things like the timing chain covers. I like the idea that even if they weigh the same, the weight is distributed lower and further forward than my SC's engine. Dangit, I really need to start saving my pennies.