Originally Posted by 86 951 Driver
I have the same issue as well. I am interested to hear what people respond with. I heard some people when the BS housing is leaking they just put some RTV or similar on the outside to stop it from leaking.
Just finished this job this weekend... not terribly hard and I'm a novice.
Learned so much seeing in 3 dimensions.
Unless I'm way off, the coolant flows within the housing and enshrouds the oil cooler... Really allows us to run the car at high rpm's for hours with manageable oil temps. With the n/a engine having the housing right under the hot headers makes me wish I had the Turbo's external mounted cooler.
My oil leak was passenger side and drenched my sway bar bushings, control arm bushings and power steering boot. Driver side bushings are nice and dry.
Dripped oil from the oil cooler housing gasket right above the OPRV.
Verified same by degreasing & hosing the undercarriage; idling for 5 mins and looking for drip path. No milkshake but I was darn close by the looks of the seals. Another month and the oil nozzle o-ring would've failed thus introducing oil in to the cooling system. I'd assume the much higher oil pressures vs coolant pressures would result in far greater oil intrusion than vice versa.
Anyway, used Clark's and 944Foot2the floor... yes, terrific both.
1. We left ON the headers but removed the heat shield; removed PS pump and hose. Drained oil and coolant.
2. Bought the Pelican Oil Cooler seal kit for $36 and had everything needed.
3. Tested the oil cooler itself for cracks/leaks... tight. Installed a new Oil Pressure sender.
4. Thoroughly cleaned the 24-year old gasket gum/varnish off the block and the housing rim. Cleaned and tested the OPRV for 10 LBs actuation.
5. Changed the included gaskets and o-rings. Re-installed the Rubik's cube of the oil cooler & housing up onto the block. Slowly tourqued then inserted OPRV slowly. Re-installed heat shield. I have the '88 one-piece OPRV... and had to tap&die the threads due to a quarter century of heat cycling.
6. Loaded 2 gallons of distilled water and 4ounces of SHOUT to coolant system.
7. Loaded 5.9 quarts of 5W-30 to idle engine and prime oil pump. OC142.
8. Ran engine for 5 minutes with coolant bleeder open till fluid emerged.
9. Flushed oil and laundry fluid. Opened the coolant block nut to expel all fluid from block. Flushed another 2 gallons of distilled water to clear SHOUT and any oil from radiator system. Installed a 2nd OC142.
10. Reloaded with 15W-40 Rotella and 2 gallons of Zerex G-05 50%.
11. Enjoying no drips, nicenon-bouncing oil pressure and no milkshake fears.
Total net time: 6 hours... and yes we had a lift.
Thanks to Mark for his guidance and awesome set of tools.