Question regarding oilcooler
 

I dont know if Im extraordinarly stupid or something but about a month ago I took the engine out of my 85A to reseal it. I kinda got stuck on the oilcooler/heatexchanger thou and thus havent touched it since because until I know how its supposed to go back together I dont want to put the engine back in.

I ordered a sealkit with the big rubber/steel gasket and a number of big O-rings and a few metal washers. I got one black big gasket and one clear, the clear one is a bit bigger than the black one. Then I got two green O-rings but I know they are for the oilcooler itself. My issue is that I dont know how all the gaskets are supposed to go on the housing.
When reading the instructions it tells me that Im supposed to use a plastic washer in the bottom and then shim it to the correct spec. My problem is that I didnt get a plastic washer or any shims, just a bunch of washers but theyre all metal.
So I called the guy I ordered the kit from, and he told me that hed send me the correct parts again. 3 weeks later I recieved another clear gasket and another washer....

So. Where is the clear round O-ring/gasket supposed to go? Where is the black one supposed to go? Do I need the plastic washer and the other washers? I didnt have any plastic washer there when I took it off, neither did I have any shims.
Once again, I have read the instructions several times, but it makes no sense to me looking at the parts I have.

Also I have the old oilpressure relief valve, do I need to replace it? I dont have the alignment tool either, do I really need it? Feels like the old spring system would be less sensitive to missalignment?

Here is a u-tube video, its not as bad as you think. Just did my second reseal Saturday on a friends car

www.youtube.com/watch?v=5zZLHAqXxwM

And here is a good write up on it scroll down towards the bottom of the write up for seal replacement

http://944foot2thefloor.blogspot.com...-oprv-oil.html

http://www.clarks-garage.com/shop-manual/lube-01.htm

That should answer all your questions.

Ive watched the youtube video before in my search for this. Ive read the instructions from clarks-garage, I even printed it out.
As I said earlier. Looking at the gaskets and rings I have it makes no sense at all. I simply dont have the plastic washer or the 0,5 mm shims theyre talking about and noone that I usually order parts from even know what they are. I ordered the sealkit but all I got was the two green o-rings for the oilcooler, one black round washer, one clear round washer, a bunch of metal washers and the big gasket for the housing itself. Also there wasnt any plastic washers or 0,5 mm shims on it when I took it off either.

This is becoming extremely frustrating, I was supposed to have my first race of the season this weekend but that aint gonna happen.

Sounds like you have all the parts you need. The shims are the "metal washers." Why your car didn't have them is beyond me. Possibly a shoddy repair by a previous owner or shop or it was within the .25mm spec without any shims. I did a search and found quite a few threads of people doing this job on the NA engines.

Is this what you have?

http://944online.com/images/products...olergasket.gif

The video showed everything very clearly.

Yea but once again I dont have the plastic washer, I only have a thick clear gasket. Its as thick as the black gasket. According to the video its supposed to be a plastic washer and not a big gasket and the one displayed in the video I simply dont have.

Why don't you take a photo of what you have. Who do you order your parts from? I've ordered the seal kit multiple times from several vendors and they are always the same.

Make certain you test the cooler before installation.

For it to be a viable test, it must be done with water heated to approximately 89 degrees C. in order for the element to expand and give a true indication of its condition.

The cold water test simply won' t do.

Personally, I would do away with the silly contraption altogether.

http://clarks-garage.com/phpBB2/view...766&highlight=


Bring it.

I can take pictures of what I have, just not right now I dont have my garage at home. Ill probably be going there tomorrow thou so I can show you then.
Im usually ordering from 944Online and Ive always had great experience with them. But this time I ordered from a local guy that everyone claims to be so good, mainly cause it was supposed to be quicker delivery, which it wasnt I might add.

Marajit. I dont think thats necessary there was nothing wrong with it when I took it off. I only pulled it apart cause I was resealing the whole engine. It started leaking oil badly from basicly everywhere after I put fully synthetic oil in it not knowing what the previous owners had used.

I think I can conclude however that I dont have the necessary washers/shims. Im thinking about returning all the stuff I bought and just get the right things from Ian at 944Online instead, atleast then Ill know Im getting the correct stuff. Might aswell get the alignment tool and a new oilpressure relief valve while Im at it then.
Or doing like Marajit said and get rid of it. Thing is this car will become a racecar so maybe it would be better to get rid of the watercooler and get a proper aircooler instead. Ive always been a bit afraid that the oilcooler might heat up the water when racing?

EDIT: I think I might actualy do that. I can borrow the housing and hoses and cooler off my Turbo project car. Would definately make life alot easier, plus it would be healthier for the engine in the longrun. What do you guys think?

Make sure you use the right OPRV.

I have been told that the Turbo filterhousing will not fit my block?

Also if I decide to keep the oil/water cooler because rebuilding it to a aircooler seems to be too much hassle right now, can I keep the old style OPRV? Or do I need to replace it? A new one is close to 500 dollars!?