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Patrick
 
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Replaced original water pipe with a shiny new one...

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1984 944 NA, constant tinkering
Old 10-03-2020, 06:59 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #3401 (permalink)
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My cooking/operating room references are escaping me, but that is one clean bay!! Shine some more light on that manifold (esp. studs & nuts), as it's worth showing off as well
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1984 Porsche 944 (Project 1)
1992 Mazda MX-3 GS (Project 1.5)
1992 Volvo 740 Turbo Wagon (Project 2)
2005 BMW 330xi
2017 Subaru BRZ PP
Old 10-04-2020, 06:28 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #3402 (permalink)
Patrick
 
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Decided to perform more surgery on the car this weekend. I've been putting up with an oil leak that's been bleeding over the power steering pump bracket and steering hoses, then drip on the cross member, then on the belly pan and finally to my oil catch trays.

I've had enough!! The only external engine assembly I haven't touched yet was the formidable oil cooler so off it came last night - This is what I found:


There were three distinct O-ring gaskets (main cooler housing O-ring was orange) and this lower one was completely disintegrated. Thankfully, I had the foresight to order a replacement last year as I knew this was going to come up at some point.

BTW: Anyone saying that these oil coolers can be removed without removing the 1/4 cylinder exhaust header is either a magician or smarted than me (I gave up after about 2 hrs of fiddling...). I also read that moving the power steering pump out of the way helps - YES IT DOES!! I think I'd rather replace a clutch then do this again. Removing those four bolts and housing sucked big time. Re-installing the bloody thing was also inspiring ("I picked a bad time to stop sniffing glue..."). Having the alignment tool slide in smoothly was a true test of patience (and yes I did have the four bolts very loose while trying to wiggle the housing around.

Sorry for the rant, but this job kicked my butt... On the plus side, everything went back together and, once filled with nice fresh oil and coolant, she sang her aria without hesitation. I'm being cautiously optimistic but the chronic oil leak may finally be addressed, let's wait and see...
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1984 944 NA, constant tinkering
Old 11-14-2020, 05:51 PM
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Patrick, hopefully I got my cooler reseal right when I did it (on the engine stand .... where it’s a million times easier!)

Best, John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 11-14-2020, 06:56 PM
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Patrick
 
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John,
I would like to go over some details with you regarding this install. I ran into a couple conflicting situations that didn't make sense. Thanks!
Patrick
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1984 944 NA, constant tinkering
Old 11-14-2020, 07:24 PM
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I didn’t have/use a tool ... just incrementally tightened the housing while fitting the OPRV for a good feeling alignment. But the motor was on a stand, so all very easy.

As said, hopefully I got it right.
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 11-15-2020, 05:02 AM
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Quote:
Originally Posted by pfarah View Post
BTW: Anyone saying that these oil coolers can be removed without removing the 1/4 cylinder exhaust header is either a magician...
I have done it twice without removing the exhaust. The power steering pump needs to be dropped first. It helps alot if the water pump is also removed but can be done with it in place, too. The trick is to have an assortment of swivels and a 1/4 and 3/8 drive socket. A swivel extension is far better than a universal. Once the bolts are loose a flexi extension on a nut driver makes getting the bolts out and in a snap. Have a tap handy in case any of the bolt holes get damaged.

If you are changing the water pump I would do the oil cooler seals at the same time. I think the right engine mount is also more accessible with the OC and WP out IF the mount and bracket are removed as one. The right mount is the one that is usually shot due to the heat form the exhaust.


Last edited by djnolan; 11-15-2020 at 05:37 AM..
Old 11-15-2020, 05:11 AM
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Patrick
 
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Hey DJ,
Removing the bolts wasn't the problem, trying to manipulate the oil cooler assembly out of the car was impossible until I removed the one header. You're absolutely correct about doing this while you're in there with other stuff. I had the exhaust manifolds ceramic coated late last year and actually remedied an oil leak on the lower balance shaft housing (which required me lifting the engine up some). I was right there! I guess you can't fix stupid...
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1984 944 NA, constant tinkering
Old 11-15-2020, 07:32 AM
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Patrick,
I think I was able to remove the cooler by removing the ps pump bracket and the heat shield. I needed a 3rd hand to hold it in place to get the bolts started. I tried to remove the header first using stud remover and gave up. The header cracked and in the long run had to remove the headers anyway. Much easier with the WP and PS pump out of the way.
Old 11-15-2020, 09:42 AM
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Patrick
 
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I did remove the heat shield and moved the power steering pump out of the way with no success. Fortunately, I replaced all the exhaust hardware earlier in the year so everything came off easily.
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1984 944 NA, constant tinkering
Old 11-15-2020, 11:58 AM
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Politically Incorrect
 
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Today I replaced the voltage regulator on the 924S.

I removed the air filter box to get plenty of access from the top.

I've heard that some owners have done this from below.

I looked at doing it both ways, and top just makes more sense to me (took 30 minutes, start to finish, including checking the oil and coolant).
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'87 924S
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Old 11-15-2020, 04:16 PM
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Today, I replaced the engine temperature sensor in the head and solved two problems:

- It stopped the cold startup engine stumble problem that I had, and

- It fixed my erratic temperature gauge reading. It had been reading too high and had been fluctuating up and down some. Now it is reading steady, right in the middle of the scale.

Hooray, especially on the stumble cure. I had forgotten how nice it drives without the stumble.
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'84 porsche 944
Old 11-15-2020, 04:40 PM
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Cleaning up some tailight housings
Old 11-15-2020, 08:49 PM
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Kessel run in 12 parsecs!
 
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Scrubby dub dub, one dirty porsche in the tub. LOL! Engine bay was nizasty, so I scrubbe it down, looks better now..
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Old 11-16-2020, 05:47 AM
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Quote:
Originally Posted by Fast Freddy 944 View Post
Scrubby dub dub, one dirty porsche in the tub. LOL! Engine bay was nizasty, so I scrubbe it down, looks better now..
We need pics otherwise we don't beleive you
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Old 11-16-2020, 04:20 PM
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Kessel run in 12 parsecs!
 
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Quote:
Originally Posted by Ernie944 View Post
We need pics otherwise we don't beleive you
LOL!!

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Old 11-19-2020, 04:50 PM
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[QUOTE=Fast Freddy 944;11110080]LOL!!

Rigth on ,now your talking,nice & clean.

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Old 11-20-2020, 04:45 AM
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Kessel run in 12 parsecs!
 
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[QUOTE=Ernie944;11110531]
Quote:
Originally Posted by Fast Freddy 944 View Post
LOL!!

Rigth on ,now your talking,nice & clean.

Thanks Ernie 944, my finger nails and hands were dirty, thanks to Fast Orange for cleaning my mits. I go to car meets on friday evening, and everybodys under hood was show quality, but mine was pretty nisasty, so I spent a weekend cleaning and scrubbing, now I wont be embarassed.
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Old 11-20-2020, 03:16 PM
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Finally finished my clock conversion. Installed silver dots in all gauges.
Old 11-20-2020, 04:13 PM
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Kessel run in 12 parsecs!
 
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Originally Posted by 911 SLANT View Post
Finally finished my clock conversion. Installed silver dots in all gauges.
Is that a 944? Aint seen a dash like that one, round these parts.

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Old 11-21-2020, 07:30 AM
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