Rennlist Discussion Forums   classifieds | membership | rennlist | photo album    
sponsors | upload photo | chat    
 
Go Back   Rennlist Discussion Forums > Water Cooled Technical Discussion Areas > 996 Forum
Sign in using an external account
Register Forgot Password?
Search


Reply
 
Thread Tools Search this Thread
Old 06-08-2009, 04:03 AM   #1
Hambisa
Addict
Rennlist Member
 
Hambisa's Avatar
 
Join Date: Mar 2004
Location: San Diego, CA
Posts: 190
Default Oil pressure sender unit replacement - DIY

Over the past week I found oil dripping from the right cam cover below the pressure sender unit, which was very wet around the base. Then the OBC began flashing "sensor failure" messages, along with momentary heart-stopping 0 psi readings on the oil pressure gauge.
I searched this forum and found several references to similar situations, usually concluding with the dealer or indie replacing the unit. I purchased a sender from my indie ($55) and set about replacing it myself, as I wanted it done before the weekend. Here is what transpired:
1. The oil sender unit is located forward on the right side of the engine. In the first photo you can just see it behind the A/C hoses. The second photo is a closer view.

2. The base of the sender unit has a 19mm hex, and it was immediately apparent that a standard combination wrench of that size would never work in the space available (with the engine in place.) Thinking a crowsfoot wrench might be the answer, I headed to the local tool store. (For those in this area, Pat's Tools on El Cajon Blvd in El Cajon, CA, is a great resource for new and used tools of every kind.) The shank of a crowsfoot doesn't clear the base of the sender unit, so the counterman in the store went digging through boxes and bins for something that might work. He showed me the tool in photo #3, which I thought had definite possibilities, if I opened the end to the black mark so it would slip onto the hex from the side. It is 3/4", same as 19mm, and the 12-point fitting would facilitate working in a narrow confinement. They charged me $3 for the tool.

3. Back home, a few minutes of Dremel magic and a file to smooth the edges, I had a compact open-ended wrench that slipped onto the sender's hex. Photos 4 & 5.

4. I pulled the wires from the sender unit and, working by feel alone, with the tail of the wrench in the space towards the rear of the engine, easily (perhaps too easily) loosened the old sender and unscrewed it by hand. Replacing it with the new unit (which comes with a new sealing washer fitted,) I was able to get enough leverage for a secure mounting. I re-attached the wires - note: one wide and one narrow terminal, and cleaned off the dirt and oil around the base with a rag. Photo #6.

5. Ignition on, started the motor: normal readings on the oil pressure gauge, and a flashlight in the engine compartment to check that no oil was spraying around; so far, so good! My forearm wasn't entirely unscathed, however, as those tight confines have several hose clamps and other painful protrusions.

6. Like most enthusiast Porsche owners, I have been blessed with the necessary OCD, so, removing the right rear wheel, I proceeded to take off the coil shield and clean away as much of the accumulated oily crud from the cam covers and surrounding area as I could. It seems that the sender unit had been seeping for a while before the dripping made it apparent. After putting it all back together and doing a couple of hundred miles this weekend with no OBC messages, the bottom of the motor is bone dry!

I hope this DIY proves helpful to someone who, now or in the future, may need to replace the oil sender unit -- it doesn't require a Porsche shop or $400 P-tool to do the job. If a regular Rennlister needs it, I'll be happy to loan them my "priceless" tool. PM me.

P.S. Southern California + Early Summer + 911 Cab = HEAVEN!
To remove this ad, register today or login if you already are registered!

Attached Images
      
__________________
Ian . . .
'02 996 Carrera Cabriolet Arctic Silver/Black. 997 shifter, SSK and a few other tweaks.
Previous P-cars:
'91 964 Carrera 4 White/Tan. The best of the classic 911's
'86 951 Black/Black Fast & fun.
'85.5 944 Red/Black Much loved - I miss her!
'84 944 Burgundy/Tan My first taste of the P-car passion

'04 Volvo XC90 Wife's daily driver and family hauler
Hambisa is offline   Reply With Quote
Old 06-08-2009, 09:51 AM   #2
DCP
User
 
Join Date: Jan 2004
Location: Houston
Posts: 1,082
Default

Man, thank you for this. I needed it!

Very clever with the tool mod.
DCP is offline   Reply With Quote
Old 06-08-2009, 10:31 AM   #3
ivangene
Parts Specialist
Rennlist Member
 
Join Date: Aug 2008
Posts: 16,357
Default

+1 for tool tip !
ivangene is offline   Reply With Quote
Old 06-08-2009, 10:51 AM   #4
function12
User
 
function12's Avatar
 
Join Date: Mar 2009
Location: Houston, TX
Posts: 770
Default

What about one on these?
Click the image to open in full size.
Sears 19 MM Extreme Ratcheting Wrench
function12 is offline   Reply With Quote
Old 06-08-2009, 11:59 AM   #5
007DT
Addict
Rennlist Member
 
007DT's Avatar
 
Join Date: Aug 2007
Location: Alpharetta, GA
Posts: 2,583
Default

So how long did it take you... Just had it done on my car and the shop charged me 1.5 hours?
__________________
Dave______________________
07 GT3RS
04 M3 GTS3 Race Car
08 550i ///M Pkg
12' X5
15' 2500HD Diesel
28' Tag Optima (Toy Hauler)

007DT is offline   Reply With Quote
Old 06-08-2009, 02:15 PM   #6
Hambisa
Addict
Rennlist Member
 
Hambisa's Avatar
 
Join Date: Mar 2004
Location: San Diego, CA
Posts: 190
Default

Once I had the tool modified, and not counting cleaning up the accumulated muck underneath, swapping the sender units took no more than ten minutes. Nothing else has to be removed to access it (except some skin if you don't avoid those hose clamps!) 1.5 hours seems rather "generous."
__________________
Ian . . .
'02 996 Carrera Cabriolet Arctic Silver/Black. 997 shifter, SSK and a few other tweaks.
Previous P-cars:
'91 964 Carrera 4 White/Tan. The best of the classic 911's
'86 951 Black/Black Fast & fun.
'85.5 944 Red/Black Much loved - I miss her!
'84 944 Burgundy/Tan My first taste of the P-car passion

'04 Volvo XC90 Wife's daily driver and family hauler
Hambisa is offline   Reply With Quote
Old 06-08-2009, 07:11 PM   #7
007DT
Addict
Rennlist Member
 
007DT's Avatar
 
Join Date: Aug 2007
Location: Alpharetta, GA
Posts: 2,583
Default

Quote:
Originally Posted by Hambisa View Post
Once I had the tool modified, and not counting cleaning up the accumulated muck underneath, swapping the sender units took no more than ten minutes. Nothing else has to be removed to access it (except some skin if you don't avoid those hose clamps!) 1.5 hours seems rather "generous."
Strike 2 on these guys!
__________________
Dave______________________
07 GT3RS
04 M3 GTS3 Race Car
08 550i ///M Pkg
12' X5
15' 2500HD Diesel
28' Tag Optima (Toy Hauler)

007DT is offline   Reply With Quote
Old 06-08-2009, 07:35 PM   #8
wross996tt
Super User
 
wross996tt's Avatar
 
Join Date: Feb 2005
Location: Republic of Boulder
Posts: 4,074
Default

Ian, nice job. I'm sure this will help others save some $$$$.
wross996tt is offline   Reply With Quote
Old 09-03-2009, 04:27 PM   #9
deckman
User
 
Join Date: Aug 2007
Location: MD
Posts: 882
Default

I am trying to do this job right now. It's super tight down in there and the wrench I am working with is cut down to about 5 or 6". Unlike the OP, the sensor on my car is in on very securely. I can't seem to get enough leverage to loosen it. I'm tempted to take pliers to the top of the unit and try to get it loose but am afraid I'll just crush it. Then it would still be stuck and I wouldn't be able to drive the car.

Any ideas?
deckman is offline   Reply With Quote
Old 09-04-2009, 09:54 AM   #10
lotecredneck
User
 
Join Date: Jun 2009
Location: The Great State of Texas
Posts: 54
Default

Remove the right rear wheel and then remove the heat shield. You will then have a little better access to the sender where you can place the wrench on the hex part of the sender and use both hands or tap the wrench with a hammer to loosen the sender.

Tony
lotecredneck is offline   Reply With Quote
Old 09-04-2009, 02:47 PM   #11
fpb111
Addict
Rennlist Member
 
fpb111's Avatar
 
Join Date: May 2008
Location: Northern NJ
Posts: 3,129
Default

They have been using that design sender since at 1969. I wonder if it is the same part # ? Probably not the old ones were single wire.
Attached Images
 
__________________
2003 996 cab 6 speed
1972 RS 3.2 twin plug short stroke crank fire, roll bar, camber truss, factory short shift, turbo brakes sold
1970S sold
PCA instructor since 1984
Past NNJR social chair, past rally chair, past fresh sell by date
Frank

Last edited by fpb111; 09-04-2009 at 02:49 PM. Reason: spelin
fpb111 is offline   Reply With Quote
Old 09-04-2009, 04:53 PM   #12
deckman
User
 
Join Date: Aug 2007
Location: MD
Posts: 882
Default

I did finally get the unit loose using a wrecking bar wedged against it and using my body weight against it. However....

This is getting comical. I rigged a wrench like the OP did, basically cutting open a box wrench and shortening it so it would fit in the confines. I'd take a pic to show you but....it is now stuck on the bolt attached to the underside of the sending unit. It wiggles up and down and left to right, but I can't pull it off to save my life. I don't really know what to do about it.

I tightened the unit back up and went to get new tires today. I am driving with a wrench in my engine bay. But believe me it isn't going to fall out.
deckman is offline   Reply With Quote
Old 09-05-2009, 02:23 PM   #13
Dharn55
Addict
Rennlist Member
 
Dharn55's Avatar
 
Join Date: Sep 2005
Location: Wilmette, IL
Posts: 1,822
Default

OK folks here is the tools that makes this simple. A 19mm Crowfoot wrench. Use this with a 3/8" universal, extension and socket wrench and the removal is simple.

Jack up the car, put in a jackstand, remove rear right wheel, slide the crows foot wrench in from the bottom, you need the universal to get the wrench on due to the angles around the spark plug shield. A little twist on the socket wrench and it loosens right up. the just spin it out from the top, spin the new one on and tighten it down with the crowfoot. Really easy and fast.

Got the crowfoot at NAPA, here is a link

http://www.napaonline.com/NOLPPSE/(S...cf19m&Ntk=Part Number&N=0&Nty=1&D=ncf19m&Dn=0&Dk=1&Dp=3

Probably available from other sources. Made the job incredibly easy.
Attached Images
  

Last edited by Dharn55; 09-05-2009 at 02:24 PM. Reason: typo
Dharn55 is offline   Reply With Quote
Old 09-14-2009, 06:09 AM   #14
Schützenweber
User
 
Schützenweber's Avatar
 
Join Date: Apr 2009
Location: Newport Beach
Posts: 71
Default

Last night it happened to me ..

The OBC signaled an 'Oil Failure' message and my heart also stopped upon seeing the Oil Pressure Gauge dive from ~5 bar to zero while speeding down the freeway!

The Horror, the horror ...

I knew something was screwy as the needle intermittently bounced back and forth from zero to 5 bar; temp was normal and I check the oil ritualistically.

The Gauge started operating normally again at lower speeds and I didn't stop.

Good thing for the search engine here. I do hope it's the sending unit.

Time to see the dealer for some CPO warranty work!

Thanks for the valuable info.
Schützenweber is offline   Reply With Quote
Old 09-14-2009, 08:15 AM   #15
deckman
User
 
Join Date: Aug 2007
Location: MD
Posts: 882
Default

When you take it to the dealer it won't show any codes when the check and they won't be able to repeat it so their normal reaction will be they can't find anything wrong. I did this twice while the car was under CPO. Tell them exactly what happened and tell them you know from research it is the oil pressure sensor part # 996 606 203 02 that needs replacing.
deckman is offline   Reply With Quote
Old 09-14-2009, 08:15 AM
Rennlist



Paid Advertisement
Reply

Tags
2003, 335i, 911, 996, diy, failure, location, motor, oil, porsche, pressure, replacing, sender, switch, unit

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Forum Jump


All times are GMT -3. The time now is 08:36 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
SEO by vBSEO 3.6.1
Copyright © 1998 - 2007 Rennlist.com

Advertise on Rennlist - Privacy Statement - Terms of Service - Jobs