Oil Cooler Swap?

[JFP in PA]

Originally Posted by seventythree

I am going to install an S oil-cooler on my 2002 base and have the following question:

1) Can this be done without removing, or otherwise lifting, the intake runner?

2) How many O-rings will this require? The Porsche parts diagram I have access to lists the following O-rings:
- 999-707-409-40 RUBBER O-RING 2 $1.61
- 999-707-389-40 RUBBER O-RING 4 $0.66
- 999-707-344-40 RUBBER O-RING 4 $6.39
What is the really expensive O-ring for?

3) I will drain the cooling system prior to removing the oil-cooler. Can this be done without draining the engine oil? Does the engine oil automatically drain out of the cooler, or will it spill all over the engine upon removal?

4) What is the vacuum line connecting to the top of the oil-cooler?

TIA

(1) Yes, but you will need to pull the air tube running from the air filter to the intake.

(2) Four in total; two large and two small. Porsche has updated the numbers on these, so go with the dealer info. Last set we purchased ran about $15 for everything...

(3) Drain the coolant, you do not need to drain the oil. Before lifting the old cooler out, slide a large pastic bag under it to catch the oil and coolant that did not drain down, otherwise you will be cleaning up one Hell of a mess on top of the engine, plus you will prevent oil or coolant from getting into the wrong passages and creating new poblems.

(4) The line on top of the cooler is a water return line to the surge tank in the rear trunk. It is critical that it be reattached as the oil cooler is the highest point in the cooling system, and will be where any air will collect. That line gets it out to the surge tank.

To do this job properly, you will need an inch pound torque wrench to torque the fasteners (then only go 7 ft. lb.). While the cooling system is drained, it would also be an excellent time to swap the thermostat for the 160f unit.

[schoir]

Originally Posted by JFP in PA

...
(4) The line on top of the cooler is a water return line to the surge tank in the rear trunk. It is critical that it be reattached as the oil cooler is the highest point in the cooling system, and will be where any air will collect. That line gets it out to the surge tank.
...

On 1998 and 1999 Boxsters, I believe the oil cooler line goes from the top of the oil cooler to a tee, which then splits off with one line going to the coolant tank in the trunk and the other line going to a nipple at the oil pump housing at the front of the engine.

I saw a 1997 Tiptronic this past weekend at a TSBL event and the oil cooler had no line at all on the top of the oil cooler.

I looked at the front of the engine on a 2001 and there was no outlet (nipple) on the front of the oil pump housing. So, I think, in that case, there is only the line going from the top of the oil cooler to the coolant tank.

What is the reason for the set up in the 1998 and 1999's?

Regards, Maurice.