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944 S on a 1988 M44,40: OPRV and Oil cooler removal and refit due to oil leak

jellytott

jellytott

Member
Hi
MY PROBLEM
Oil coiler and OPRV replacement,, here goes.
Done the following in paragraph below, completed works and started her up, the oil filter seal failed within seconds pushing out oil at high
pressure everywhere, hoping it was just "the oil filter" not tightened up correctly. I removed and seated oil filter seal again, started up
same,,, tried another oil filter and same again I lost 4 ltr of oil in no time at all my inspection pit looks like an oil bath and me
absolutely p*ssed off too.
Oil guage showed 4 to 5 bar (normal) when the oil filter fails it does go with some force and squeel too with the resulting pressure I assume and hope, I have only run it for seconds each time.

REASON WHY
Started with that common oil leak LHS (PAS pump side of engine) the clues,,, oil puddles when left parked, also covers
the PAS pump with oil plus smells oily when hot after long runs. The quick fix of tightening up the 4 housing bolts failed to stop the leak so decided to get it sorted. I knew and researched parts and technique, so the 944 had 2 types of OPRV early and late *** (the early Oil Pressure Relief Valve made up of 3 parts nut, spring and piston these early types basically covered 83 -86, then after this early type a new "one piece OPRV" covering 1987 and some 924S this 2nd one piece replacement also now replaces the early 3 part OPRV piece too).

I followed the plans available from various sources and ordered parts from the Dealers, plus sourced the allign tool off the for this forum
too from a helpful forum member. Knowing there's 2 types of OPRV these are year bound I worked out mine being a 1988 was the later
type being the larger 24mm nut OPRV requiring just the crush washer (part 34) and oil ring (part 45 or 45A), along with new oil cooler housing seal, shim washers and oil cooler orings too.

So, I have since found out there are infact 3 types of OPRV,s
1- the smaller nut type (3 part type which is N/A)
2- a 24mm OPRV (1 piece) part no 944 107 035 11 I beleive this requires tool 9215** this one I have and used.
3- then a 24mm slightly longer OPRV (still 1 piece) part no 944 107 035 01 alignment tool rquired 9262/1

Basically, I was completely unaware there are in fact 2 type's of 24mm late OPRV and 2 type of allign tool too, I've used the slightly shorter allign tool 9215 for the longer OPRV part 944 107 035 01, of course a double wammey when used the shorter 9215 tool allign in the Cooler housing here so using it appears things where "nice and true" for the OPRV to site into the cooler housing and Engine block, I only felt a bit of presure difference when I inserted the complete valve and just thought the o-ring was pushing home...how wrong I was!

My question to those clever mechanics or those with a brain the size of a planet!
1) have I caused teminal damage to the engine??
2) I have removed the OPRV, the o-ring isn't damaged but half way along shaft it is slightly polished I suppose when inserted into cooler housing/block not being true in shaft/bore to housing.
3) Have I damaged the existing OPRV valve?
3) Anyone got the longer 9262/1 allign tool for the longer OPRV I've got?

Thanks in advance

John
presently very very feed up :-(



 
Don't think that you will have done any damage, one of our 968 owners had his OPRV fail at 7000 rpm on the Clarke straight at brands, dumped the oil and a fire in the engine bay, but the engine was ok

i have read two instances of the housing being warped and locking the OPRV they can be very hard to get aligned correctly, have you looked up the hole to make sure the gasket is in the right place.

 
Thanks Waylander,

From that incident its re-assuring to hear the engine was still OK still mine only run seconds from start up, I'm pretty confident the gasket aligned ok but unsure because I used the shorter align tool it may not be?

Hopefully some-one may know or suggest where I could have loan the 9262/1 the longer align tool or any advice still.

Like all things like this its a pretty horrible feeling when it goes pear shaped, I was pretty careful but not careful enough, I have

picked up on a couple of posts on other forums blowing the oil filter seal but haven't mentioned why, I think I have out its possibly due to the wrong tool used.

 
The main issue I had was that if the boots in the housing were just finger tight the align tool would screw in and out easily but as I tried it tighten them up it would make the alignment tool harder and harder to twist,

It took a long time to get right and that included a visit to a surface plate and a a sheet of emery paper.

you need to be able to remove the alignment tool with all the housing bolts torqued up using just the power of your fingers

hope that makes sense, you can get the longer tool from your local dealer

 
Thank you yes it makes good sense and good advice about being to move the align tool with just finger pressure when screwing in/out, I suppose you had a couple of attemps with your OPRV and was quite happy when fitted correctly in the end for you, hopefully my OPRV part is still fine with being wrongly seated, you mentioned a polish up I assume on the OPRV shaft ??

I've posted too l if I could loan from a forum member how may have the longer type 9262/1 align tool for a piece OPRV for 944S, its a shame to spend £40 for a one fitment use.

Also, this next time I buy some budget 10/40W semi synthetic rather that seeing quality Mobil 2000 on the floor!

 
Using the right OPRV tool (9262/1) has resolved the issue that I had earlier with excessive oil pressure blowing the oil filter seal off and loosing 5+ Ltrs of engine oil within seconds with a few repeated starts.

Thanks to Waylander for the advice on the techque using only finger pressure to screw in the align tool, I was expecting a bit of a chinese puzzle doing the 4 bolts in sequence to tension down to the

correct torque yet maintaining finger pressure on the align tool, but I had luck with me the 4 bolts pulled in true without to much trouble...phew!!

More importanly the oil stayed within the engine too !

 
Phew - glad you got it sorted in the end, there's no better feeling than everything working, nothing leaking and no spare parts left over!

 
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