Oil cooler problems....

[NewPoCo944guy]

I just did the oil cooler seals on my 86na 944. I seem to be getting oil into my coolant, but no coolant into my oil. I've got the older housing(nonupdated) so I didn't use the plastic washer that goes between the cooler and the element. It was after running the car for a few minutes that I noticed "foam".....oil in the coolant recovery tank. I drained everything out and then reinstalled everything....including that plastic washer .....and then the same problem.....oil in the coolant, but no coolant in the oil or on the dipstick or oil filter. Did the oil cooler element go bad? If so can it be tested? It did look like a little bent where this plastic washer goes. Do I have to switch to the newer type of housing used on the 944? What have I done wrong? I've also changed the belts, seals and water pump without any problems...help

[mbwilser]

Did you flush the coolaing system adequately? Some advise running some "soap and water" through the system a few times.
Might the oil be residual as there are lots of places for it to hide?
MW

[FLA944]

Dis u flush the coolant system? A vinegar and water solution works well and no foaming.

Did u use the alignment tool? If not get one and re do the install.

Rick

[NewPoCo944guy]

I flushed the oil out with dish soap and running water into the coolant recovery tank. I still watched the oil level on the dip stick go down. I didn't use the alignment tool for installing the housing, I just aligned everything by hand and carefully torqued the bolts up. This problem is driving me crazy and my knuckles raw!!

[strath44]

Did you do this job with the engine in if so whats the access like and how long did it take to get the housing off the first time?

[FLA944]

Aligning the housing by hand is touchy/fealy at best. I tried then had to do it all over again with the alignment tool( same result u are having now)

Access is adequate if you have a 2nd wrist. I pulled the exhaust manifold allowed alot more access.

mark the oil pressure sensor wires so as not to install incorrectly.

Rick

[strath44]

can the alignment tool be fabricated if not how much is it (know there are different variants of the tool for different housings - as listed on clarks g - but don't know what they like!)

[FLA944]

The alignment tool is based on the OPRV. You have an early OPRV and the tool is available here @ Pelican and only $16.00usd. The part # is PEL-TOL-P218.

Also, before installing assure u have the right amount of shims so that the cooler is parallel with the housing.

Rick

[NewPoCo944guy]

I removed the housing with the engine in and the exhaust manifold on. The oil pressure sender and power steering pump had to be removed in order to remove the housing. It took about 2 hours to remove and 3 to install. I think that maybe I should remove the houseing, pull the element, pressure test it(see if it leaks) then reinstall without the plastic washer and use the alignment tool. Then flush the system with water and vinegar and see if this system works. My hands are getting raw!!