Installing oil filler baffle

[deserttoad]

I'm sure this has been covered, but I can never quite figure out how to properly search the forums.

I purchased the oil control baffle from 928 Motorsports that goes under the oil filler. I'm wondering if I can slide it in after I've removed the mounting bolts and hose and can lift the filler up. I've read too many horror stories about removing the water bridge....

1979 Euro

[Bills928]

You have to remove the bridge to install it. The only issue in removing the bridge is getting to and removing the 4 hex bolts. They are usually frozen on and getting an allen wrench on them without stripping is usually the problem.

[Opelotus]

Removing the water bridge can be difficult if the bolts haven't been touched since the factory installed them. The key here is patience... you want to avoid snapping the bolts if at all possible. Also plan on replacing the bolts once they are removed.

I found that a combination of tapping the bolts repeatedly with a hammer and a long punch, heat cycling with a small propane torch, and penetrating oil works pretty well. Repeat as necessary until the bolts break loose, then work them in and out (they tend to tighten up again after a couple turns CCW) until you can remove them completely. I was able to remove all 4 original water bridge bolts on a '78 that were severely corroded without snapping them using this method.

Then chase the threads, install new gaskets and bolts with anti-seize (or non-hardening thread sealant) applied

[Mrmerlin]

also consider to drill a small hole into the water bridge so it will go into the bolt shank hole,
then fill the hole/ well with PB blaster,
of course it would be goo to drive the car for a while before trying to get these bolts out.

[deserttoad]

Thanks all for the advice. Been soaking with oil daily and giving all the bolts a good whack with a hand impact wrench. Fingers crossed.....

[qdac]

I did this recently on my 1981 US 4.5L model. I was replacing all gaskets & so I did remove the water bridge, but I do not believe that it is necessary to remove the bridge in order to remove the air / oil separator.

For me, the big trick is that the air / oil separator has two bolts - one on the passenger side (the side that is opposite to the distributor) on the OUTSIDE of the air / oil separator, and the other bolt (the one on the distributor side) that is INSIDE the air / oil separator. It took me a while to find it since I did not realize it was INSIDE the unit. Just remove the wire screen, look down inside the unit & you will see it.

The order of replacement for the water bridge and the air / oil separator is important - IIRC you must install the water bridge first and then the air / oil separator. I remember doing it the wrong way first when re-installing this stuff. Try removing the air / oil separator cap, remove the wire screen, disconnect the hose down to the oil pan, then the two air / oil separator bolts, and then gently lift the unit up. It *should* be easy.

IIRC, I had to REMOVE the distributor to get to the water bridge bolts on that side. Make SURE that the distributor is set to Cylinder 1 BEFORE you do this.

[Carl Fausett]

If it helps, we have two sets of instructions for installing that baffle.

One is for installing the baffle only, and the other is for installing the whole improved PCV system.
They are on this page: 928 Motorsports LLC ® - Product Installation Guides
In the engine section

[deserttoad]

Surprised this thread is still alive. I did get it all done, turned out the real nightmare was breaking the water bridge bolts off going into the heads.... heating, drilling, easy out, break easy out, dremel, heli-coil.....

Was good times.