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YOUR RESEARCHBig Fluid Leak
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Check battery cables ..all good
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Suggestion
I'm replacing a 2yr old AOS just because it's a pattern part and I don't want it failing 2 weeks after the engine goes back in.
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Hi Guys,
New owner again, 2003 996 4S
I have attached photos I have a massive coolant leak. It seems to be coming from the back of the engine just before the transmission driver-side. I don't know what this part is. Any ideas?
Thanks in advance.
Yes it's the oil cooler
Have you got any intermix? Hopefully not
It is possible to change in the car I think but so much easier with the engine out. I'm doing mine just now along with lots of other stuff.
No intermix but I really don’t want to pull the engine out as you know if I do that I am going to have to put thousands into it doing all the other things you should do with the engine out.
4 x M6 Cap head bolts hold it down , one of mine rounded out so I had to drill its head off, easy on the engine stand but impossible in the car.
I'm not sure lowering it at the rear will help either as cooler is at the back.
I've gone with a 997 one as it's taller but D911 haven't any in stock so I'm waiting for it. O rings are separate from Porsche which is a joke.
This is fun...
Well for some of us its fun...
Depending on what your car has had maintenance wise recently, it way not need much else doing. So might not be as bad as you are imagining.
I'm replacing a 2yr old AOS just because it's a pattern part and I don't want it failing 2 weeks after the engine goes back in.
Also..
Oil pressure sender (age)
Oil level sender (faulty)
Fuel pressure regulator (age)
Checked all the battery cables ..all good
Injectors ...possibly
and Oil cooler !
No need to drop the engine at all. Not that hard a job either, just time consuming stripping stuff out. Just lower the engine on the rear engine mounts then strip the drivers side manifold out. Unbolt the old oil cooler, clean everything up, fit a new one with seals and put everything back together.
Some snaps here:
Thread 'Oil Cooler replacement'
16 Jun 2023
For a year or so I've known my oil cooler was getting to the end of it's life (coated in pink fluff). At my yearly service last month my mechanic informed me it was now weeping and could do with changing. Knowing what's involved I didn't want to tackle the job myself so booked it in with him to do it.
Just picked the car up with new cooler fitted as well as new seals, coolant and inlet manifold gaskets. Price came in at £704 (inc.VAT) for Mahle oil cooler, seals, manifold gaskets,anti-freeze and 8 hours labour. Some of the inlet manifold bolts were seized in and the engine mounts also...
Alex
Replies: 1
Forum:
Porsche 911 996 (1997-2005)
There is a video on the FCP Euro Youtube channel
Battery Disconnect & Airbox Removal- M96 Coolant Drain Procedure- M96 Engine Oil Drain Procedure - Drive Belt Removal- Supporting the Engine With a Jack - Throttle Body Removal- Air Oil Separator Removal - Plenum Removal- Hydraulic Fluid Extraction & Reservoir Removal- A/C Compressor Removal - Right Side Manifold Removal - Old Oil Cooler Removal - New Oil Cooler Instal- Intake Manifold Install- A/C Compressor Install - Plenum Reinstall - Hydraulic Fluid Reservoir Install- Throttle Body Install- Drive Belt Install- Airbox Install
I think it's a bit much for me but their oil cooler kit is great value it is in the US though.
So I have decided to do the work myself and I thought while I'm stripping that much out of the engine down I may as well go ahead and replace the coolant tank and the AOS and of course the oil cooler. I think it's going okay, but I had to break something, it's 20 year old plastic so I think I've broken the throttle body electrical connector. I managed to get it off but I think I broke one side. Don't know if I'll be able to find a replacement I will just have to strap it in place somehow.
Hi guys, so I've started with removing parts to get to the oil cooler and I found this sensor I think just lying between 1st and 2nd manifold on the right. It looks like it should plug into something, but I did not unplug it. Anybody know anything about it?
