I am finding traces of oil at the end of the interooler hoses (around the entire diameter coming out just above the clamps that secure hoses to bottom of intercooler). I have read Kevin's postings on oil filters and turbos, lots of great reading but I find nothing mentioned as far as oil up in the intercooler. My car is scheduled for 60k service next week and will bring this to their attention. Are the two words "oil" and "intercooler" words that should never be used in a sentence? I am trying to prepare myself...ok, really prepare my wife for a big bill. Any input here would be great..thanks for reading. Aaron

 

That's where the oil ends up if it's overfilled or the filter check valve is bad. Don't let them talk you into big buck repairs until you have tried the cheap fixes and cleaned the intercooler and hoses as well as possible.

 

By cheap fixes I'm assuming were talking new Porsche oil filters? I think I will also have intercooler hoses replaced since I do not have the newer ones (orange at the end). Anyone recommend having the 996 check valves and oil lines put in?

 

Buy the oil feed line check valve kit from Kevin at UMW. This was the fix for my car and every other 1996-1997 TT. These check valves are the ones that Porsche uses on the 996TT.No oil in the intercooler
and no smoke on start-up.

 

Oil over-filled

Faulty oil filter.....

Then a failed turbocharger...

The sad thing is, if you rip the turbochargers off and repair them and don't deal with the above items you will have the issues re-appear..

 

I've done the reading--no MAHLE oil filters, only original Porsched filters. However, do the Porsche filters sometimes fail? Anyone with Porsche filter failure. Could it be our pcars are exceptionally hard on filters by design?

 

If the engine filter is overtightened the check valve can fail.

 

True. Just a good hard kill with your hands. Don't over do it with a wrench.

 

Porsche updated to a check-valve located on the lower engine case with the 996TT.. Folk you have 9 quarts of oil sitting high above the center line of the crankshaft which to seek a even level. There is alot of "Head" pressure trying to make it past the check valve in the oil filter..

However, there has been recalls with that check valve (with the 996TT)due to it being STUCK.. Ouch, that doesn't do well with oil pressure and circulation for the bearings..

 

Hi mate,
I am exactly where you are,had genuine filter fitted and oil change ,then oil everywhere smoking on startup, oil dripping into heat exchangers,my fatal combo was,filter/level/viscosity,now running just over half full of oil,if you go for a 50 mile drive and continuosly floor it overboosting it,when you stop the smoke is frightening,but the next time there is hardly anything,no smoke just a bit of oil in pipework,mine was seeping from same place but has stopped now I think the hoses should be changed but reccomend fitting the valves, dont think it is very expensive,I think it will take a long while to burn all the oil out...I ve emptied turbo sumps twice now no oil comes out fingers crossed all ok,good luck
Gary

 

nb
my filters were porsche,am going to see how it goes before fitting valves,how reliable are they as a part?,what will happen to the engine if they fail under load?, I bet it woulnt just damage turbos only ifs and ands I know but worthy of comment I think,also being made of inferior 996 metal.....sorry my little joke there.
Gary

 

Gary, looks like I'm in the same boat, OEM filters but based on the threads oil level too high and some oil residue in the intercooler and hoses. Oil level now at a more realistic level and hoses and cooler cleaned as best as I can - been interesting to hear the experiences of others.

 

I think I remember reading something like having SOME residue is OK, but not if it's pooling oil....how much oil are you seeing up there??

 

ok now oil gone no smoke,
gary

 

Checked my intercooler again, does not look as bad some slight residue and thats following a short run last night. On start up from cold after standing for 24hrs there was only the slightest hint of smoke, and it would not have been visible if I had not been standing at the back of the car. It was certainly not as bad as it was before oil level was reduced. Hopefully I'll be as fortunate as Gary11 and I have caught it before anything terminal has occured....