DDK - Die Deutschen Klassiker

I tested mine (made similar tool), and when pressurised, put them in water. I tested three coolers I have bought over the years ("no engine failure" coolers). Three coolers, 2 leaked a lot and 1 a bit.

So ordered new one from Porsche and called it a day. Same luck was with early alu-case thermostats, only 2 though.

Thanks all.
Ville - I know what you mean. I am the proud owner of several fuel pumps for MFI, which are a bit hit-and-miss for leakage.

So having established that the cooler itself was probably not the culprit, I disappeared down the rabbit hole of internet wisdom about the cooler-engine seals.
Long story short, there are various types:


...and many folks believe that not all types seal properly...

http://forums.pelicanparts.com/porsche- ... -damn.html

So I got all excited thinking this might be my problem.

I sent this pic to Barry....



... and proposed that the pattern to the left of the large hole suggests that one of the high pressure seals (at the top, out of shot) has leaked, oil has ended up in the recessed area of the cooler, and made its way out via that blackened channel. Not necessarily during my ownership.

I've home rebuilt 4 911 engines, a 2.4 and a 3.2 x 3.
I used the seals that came with the gasket kit from type911, so I presume that it is simply an aftermarket kit, nothing demon or super special.
Never had a leak ever.
The kits are year/engine type specific so I obviously ordered the appropriate kit.

They sell many seals separately, maybe just buy some, check the faces in the block/cooler they seal to and assemble the parts together, or get the same from OPC.
iirc I assembled mine dry, my last rebuild was 6 years ago.

911hillclimber wrote:I've home rebuilt 4 911 engines, a 2.4 and a 3.2 x 3.
I used the seals that came with the gasket kit from type911, so I presume that it is simply an aftermarket kit, nothing demon or super special.
Never had a leak ever.

Thanks Graham. Barry was similarly the brains of the party. He pointed out that my leak happened even when turning over on the starter to get a bit of oil pressure before the first run. So at very low oil pressure, maybe 10psi. He wasn't buying my failed seal idea, and when I switched on my brain I had to agree.

So I ordered a new set of seals from my OPC, on the basis that I might as well replace them and the Porsche ones were the most likely to work.
For the record, Porsche sent the green type. Many thanks to Paul at OPC Guildford for delivering them FoC (my household is in isolation at the moment...)
A quick go in the ultrasonic cleaner, and then the cooler went back on the engine.



Oil leak almost certainly not found and fixed at this stage, but at least some prime suspects had been eliminated from the enquiry.

So it was back to looking for leaks.

Toward the "front" (fan end) of the engine, things were nice and dry. Nothing to see here, move on:




We did wonder whether the cam / rocker area might be the issue. Perhaps leaking from the back end of the RH bank down into the cooler area. But there was not much to report:



Closer inspection suggested that the leak was from somewhere higher up at the back of the engine, with oil then dripping down the case and exiting near the cooler....

Been there!
Check the small cap used for the engine breather hose and the odd oil switch and also the oil feed pipe to the injection pump off the block
It was the latter I had trouble with (hose brittle where swaged to the banjo union iirc, was 20 years ago...simple copper washer issue.
Also the rear crank seal, but that one is glaringly obvious!

I have been down the same rabbit hole too! (And always used the green seals).

Have you looked at the oil pressure switch? I know it is obvious and visible, but they can have a habit of leaking and dribbling down the case under the fan shroud and appearing to exit by the oil cooler...

Just a thought

Bit of a long shot, but I have put an ad in the "wanted" section for one of the throttle body cranks (mine went AWOL at Fenn Lane....):



If you have one, or have info about anyone manufacturing them, I'd be most grateful. Thanks!

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Richard - if you don't have any luck closer to home, it would be worth contacting Matt Blast at Eurometrix & Mark Jung at mfiwerks.com in the US

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Lightweight_911 wrote:.

Richard - if you don't have any luck closer to home, it would be worth contacting Matt Blast at Eurometrix & Mark Jung at mfiwerks.com in the US

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Thanks Andy, good idea.

Hats off to both Matt and Mark, who replied to my emails very promptly and helpfully. Now sorted (by Mark).

We inch closer to a finished car...

Cheers, Richard.

inaglasshouse wrote:.....We inch closer to a finished car......

....short lived euphoria.....gets really boring after that!

inaglasshouse wrote:

Lightweight_911 wrote:.

Richard - if you don't have any luck closer to home, it would be worth contacting Matt Blast at Eurometrix & Mark Jung at mfiwerks.com in the US

.

Thanks Andy, good idea.

Hats off to both Matt and Mark, who replied to my emails very promptly and helpfully. Now sorted (by Mark).

We inch closer to a finished car...

Cheers, Richard.

Richard make sure the throttle bodies are set up using a flow bench. It’s imperative that each throttle flows the same mass flow through each throttle. You will be amazed at how much difference in mass flow a tiny adjustment of the linkages make.

I’ve made a simple flow bench using a Hoover and a mass flow meter.

If you need any help doing this let me know and I can help.

Sent from my iPhone using Tapatalk

Darren65 wrote:

inaglasshouse wrote:.....We inch closer to a finished car......

....short lived euphoria.....gets really boring after that!

Yeah right! I can't wait to have zero projects, just driving and maintenance.
Of course I say that now...