tkacki

Hi,

Just about to replace the gasket under oil cooler housing. I don't have an alignment tool. Could You please provide infotmation about dimensions of such tooll (diameters) ? A drawing would be nice . I am able to prepare the tool myself. As far as I am concerned, there are two types of such tool - it confuses me, because my engine is 86 but stamp on oil cooler housing says 87 (has been changed by someone).

Regards,
TK

Danno

Measure the ID of the bore in the block (or measure the diameter of the relief-valve plunger). Then measure the ID of the threads in the oil-filter housing. Make a dowel tool with these dimensions on each end.

tkacki

Thanks Dano. Sound easy. So, the tool should be a custom bolt with the thread same as OPRV cap at the end and with the second end tip which fits into the engine block hole. All I have to do is to buy standard bolt and to machine the tip.

Anyone knows the tip diameter (or diameters if they vary depending on engine version) and the thread (or threads) ?

F18Rep

I cut the small end to .665 inches.

You guys make it sound so easy ;] ....Bruce

hosrom_951

You should go and see the 944 turbo and turbo S board regarding their reactions when i said that the alignment tool is critical........got all sorts of stuff from them

brad-cam

I just measured my alignment tool (the one for '87 and later) and the main part of the shaft measures 0.688".

tkacki

Thanks for responses ! And..
1 . What is outside diameter of the thread ?
2. What is the lenght form end of the tool (tip) to the begining of thread (the length of the shaft) ?

FletchDM

I have the same questions as Tom K.

So, am I understanding correctly that the large end is 0.688" and the thinner part is 0.665"? What is the length of each section? If possible, I'd like to make this tool before I pull the OPRV from the car. Failing that, I guess I can just pull it and measure the dimensions.

thanks,
-David

brad-cam

Guys,

Sorry for the delay. Here's more details - ref the following awful drawing of the '87 and later OPRV tool:



Dimensions:

A = diameter of main shaft = 0.688"
B = diameter of shaft tip = 0.630"
C = length of main shaft = 1.762"
D = length of shaft tip = 0.390"
E = diameter of threaded section = 0.778"

The overall length not including the head is 2.940"

One other point - the edges of the tip and the step from the tip to main shaft is beveled at 45" so it doesn't hang up when it's inserted.

Hope this helps. The Porsche part number of the tool is 000 721 926 21 and Pelican Parts has it listed at $45.85.

brad-cam

One more thing - looks like the threaded section is M20x1.5 mm.

Danno

You actually don't need to make it so complicated and threaded. I chucked a wooden dowel into a lathe and made one that looks like this:



The shaft part is all you need, then the short middle fits into the threaded housing (doesn't need to be threaded) and the longer larger end is just a handle to grab onto to remove. You can also buy the actual tool itself #9215 from Baum Tools: http://www.baumtools.com

brad-cam

Danno, the 9215 is the tool for the '86 and earlier I think. The '87's and later tool looks a lot different. Not sure if the '86 tool will work in the '87 and later - might do.

FletchDM

Brad, thanks man... that's perfect.

Instead of learning how to cut a M20x1.5 thread on my old SAE lathe, do you think I could get by just making it a pin like the older versions (and like Danno's)? It seems you just need to make sure the housing gets aligned so that the valve will operate without excess friction, right? So a pin design should be fine, even if a threaded one might be more "optimal." These are German cars, after all.

Thanks guys!
-David

brad-cam

David, don't know for sure, but I think a pin without threads should work just fine.

tkacki

Thank all of You for responses. I got all of data I was looking for.

Danno, is it Your car on Your avatar ? If Yes, figure out my next question .

Regards,
TK