00:00:00.299 hey guys today we're gonna be looking at 00:00:02.57000:00:02.580 some old coolers here I have the early 00:00:05.09000:00:05.100 and late housing and I'll be showing you 00:00:07.40000:00:07.410 the differences between these I also 00:00:10.12900:00:10.139 have the cooler itself in which I'll be 00:00:12.68000:00:12.690 showing you how to shim and here we have 00:00:15.95000:00:15.960 all the different OPR B's that were used 00:00:18.38000:00:18.390 over the years and finally this is the 00:00:21.92000:00:21.930 seal kit that I'll be using everything 00:00:24.59000:00:24.600 that you're gonna see is gonna be 00:00:26.50900:00:26.519 straight from the workshop manual so 00:00:29.15000:00:29.160 let's get started 00:00:33.73000:00:33.740 [Music] 00:00:41.51000:00:41.520 so alright guys for the most part I'm 00:00:44.07000:00:44.080 going to be reading straight from this 00:00:45.45000:00:45.460 tech bulletin here the first thing it 00:00:47.58000:00:47.590 discusses is the OPR V valves and has 00:00:50.64000:00:50.650 the dates manufactured now if we start 00:00:53.46000:00:53.470 reading below it it reads from the start 00:00:55.86000:00:55.870 of production 1983 1944 cars came 00:00:59.01000:00:59.020 equipped with a spring and piston oil 00:01:00.81000:01:00.820 pressure relief valve which is this 00:01:03.12000:01:03.130 right here and it says this was used in 00:01:07.65000:01:07.660 all 944 and 940 four turbos up into the 00:01:11.85000:01:11.860 end of 1986 production ok that says also 00:01:17.16000:01:17.170 early 1987 924 SS used the system so now 00:01:23.07000:01:23.080 we know that all cars up until 1986 used 00:01:27.27000:01:27.280 this and including the 1987 924 s for a 00:01:31.95000:01:31.960 certain period of time and in 1987 00:01:36.38900:01:36.399 production of 944 944 SS 944 turbo a new 00:01:41.43000:01:41.440 type of one-piece all pressure relief 00:01:43.46900:01:43.479 valve was installed which is this one 00:01:46.91900:01:46.929 here at assist at around the same time 00:01:54.38900:01:54.399 that switched your tongue at around the 00:01:56.24900:01:56.259 same time a new type of one-piece 00:01:57.99000:01:58.000 pressure relief valve was introduced as 00:02:01.35000:02:01.360 a retrofit which is this one here so 00:02:04.44000:02:04.450 basically this one here replaced the 00:02:08.69900:02:08.709 spring and piston it's all right on the 00:02:11.58000:02:11.590 next page it's showing you how to 00:02:13.23000:02:13.240 replace the o-ring and the sealing ring 00:02:15.96000:02:15.970 these must be changed every time you 00:02:18.48000:02:18.490 pull the OPR V out and here's a closer 00:02:22.92000:02:22.930 look you can see that this one has an 00:02:25.19900:02:25.209 old ring on it that I have not replaced 00:02:28.32000:02:28.330 yet I actually had the seal here and I 00:02:31.26000:02:31.270 have a light OPR v already taken apart 00:02:34.32000:02:34.330 here 00:02:34.83000:02:34.840 and you can see that there are actually 00:02:38.97000:02:38.980 two sealing rings on there one goes on 00:02:41.25000:02:41.260 one end there and the other one goes on 00:02:43.86000:02:43.870 the 00:02:44.46000:02:44.470 other end so I always try to replace 00:02:48.21000:02:48.220 both of them and this is what it should 00:02:52.59000:02:52.600 look like when you're gonna be neutering 00:02:55.13000:02:55.140 so on this side of the page is showing 00:02:57.54000:02:57.550 you that there is a steel sleeve or 00:02:59.70000:02:59.710 collar in the early blocks that cannot 00:03:02.55000:03:02.560 be removed and you must put it back in 00:03:05.10000:03:05.110 with Loctite 648 or 638 so now where 00:03:09.09000:03:09.100 you're getting into all the things that 00:03:11.13000:03:11.140 are included in the kit and the 00:03:13.26000:03:13.270 differences in the housing sorry guys I 00:03:15.75000:03:15.760 got my gasket here and I've got my 00:03:17.85000:03:17.860 packet of seals now as you can see there 00:03:20.46000:03:20.470 are two metal shims and a plastic spacer 00:03:23.64000:03:23.650 in there that means that this is for the 00:03:26.37000:03:26.380 light housing only now it is important 00:03:29.73000:03:29.740 to know the differences between the 00:03:31.35000:03:31.360 early and late housings if you read this 00:03:34.26000:03:34.270 paragraph here it says when repairing 00:03:36.24000:03:36.250 the earlier cars the new type of housing 00:03:39.48000:03:39.490 plastic washer and adjusting shims must 00:03:42.15000:03:42.160 be used that means if you have an 00:03:44.97000:03:44.980 earlier housing it cannot be used and 00:03:48.89000:03:48.900 here it has a figure 8 is the early car 00:03:52.41000:03:52.420 or original design and B is the new 00:03:54.93000:03:54.940 design now if you don't know the 00:03:57.54000:03:57.550 difference and you can't really see 00:03:59.75900:03:59.769 anything from that anyway here is the 00:04:03.18000:04:03.190 early housing you can see that there is 00:04:05.13000:04:05.140 a lip there and if I put my caliper down 00:04:08.49000:04:08.500 in there and see that it's raised up 00:04:15.08000:04:15.090 about a millimeter or so and that is the 00:04:19.53000:04:19.540 early housing and if you come over to 00:04:22.86000:04:22.870 the light housing you can see that it's 00:04:24.69000:04:24.700 completely flat there's nothing there 00:04:28.98000:04:28.990 whatsoever 00:04:31.15900:04:31.169 so you're supposed to replace the early 00:04:35.17900:04:35.189 housings with the late housings and then 00:04:38.17900:04:38.189 use the plastic spacer and the two shims 00:04:44.49900:04:44.509 all right guys here is the contents of 00:04:47.20900:04:47.219 that seal pack you can see that it comes 00:04:51.89000:04:51.900 with a black rubber ring two metal shims 00:04:56.83000:04:56.840 plastic spacer and the two oil cooler 00:05:00.64900:05:00.659 rings now we're going to start putting 00:05:04.55000:05:04.560 everything back together there are two 00:05:06.64900:05:06.659 seals on either side of the oil cooler 00:05:08.99000:05:09.000 and they will need to be replaced you 00:05:11.42000:05:11.430 just need to get up underneath them with 00:05:13.42900:05:13.439 a tool like this and they will come 00:05:16.20900:05:16.219 right off 00:05:23.58000:05:23.590 now you just take your new seals 00:05:42.97000:05:42.980 alright guys in order to do this job 00:05:45.32000:05:45.330 properly I'm not gonna be reusing this 00:05:47.78000:05:47.790 early housing so I'm gonna go ahead and 00:05:51.11000:05:51.120 set it out of the way the first thing 00:05:54.35000:05:54.360 we're going to put in is this plastic 00:05:57.17000:05:57.180 spacer now if you'll remember the little 00:06:01.28000:06:01.290 lip that's inside the early housing is 00:06:05.15000:06:05.160 about one millimeter and this here looks 00:06:09.32000:06:09.330 to be about one point seven nine 00:06:12.02000:06:12.030 millimeter so this little plastic spacer 00:06:14.81000:06:14.820 is just barely taller than the lip in 00:06:20.62900:06:20.639 the early housings but we're gonna take 00:06:24.59000:06:24.600 that push it right on to the whole 00:06:29.57000:06:29.580 cooler just like that and this is going 00:06:32.87000:06:32.880 to be the side that's going to sit in 00:06:35.30000:06:35.310 the housing like that now what you want 00:06:38.24000:06:38.250 to do is you want to take a little bit 00:06:40.52000:06:40.530 of oil and rub it around the seal here 00:06:45.52000:06:45.530 to make sure that you don't have any 00:06:47.87000:06:47.880 binding and this doesn't twist because 00:06:50.42000:06:50.430 if it rolls or twists all right it just 00:06:59.45000:06:59.460 popped in 00:07:01.37000:07:01.380 and there we go so now that I have the 00:07:04.82000:07:04.830 heat exchanger in the housing I'm going 00:07:06.65000:07:06.660 to show you how to install the shims the 00:07:09.11000:07:09.120 first thing you're gonna need is a 00:07:10.43000:07:10.440 feeler gauge set to 0.25 millimeters and 00:07:15.31000:07:15.320 a straightedge of any kind and what you 00:07:20.90000:07:20.910 want to do is you don't want the gasket 00:07:22.97000:07:22.980 on here or any shims on there yet you 00:07:25.73000:07:25.740 just want to lay your straight edge 00:07:28.13000:07:28.140 across the shoulder of that boss there 00:07:32.03000:07:32.040 and if I can get this to focus and you 00:07:36.89000:07:36.900 would see that perhaps there is a little 00:07:39.35000:07:39.360 space between that there and I'm gonna 00:07:47.51000:07:47.520 go ahead and put a shim on and that 00:07:52.82000:07:52.830 needs to be perfect right there 00:07:54.77000:07:54.780 now if it wasn't touching you'll want to 00:07:58.61000:07:58.620 take your feeler gauge and see if you're 00:08:04.40000:08:04.410 within the spec here now if I take the 00:08:09.05000:08:09.060 shim off again you'll see that even 00:08:14.06000:08:14.070 without any sort of 00:08:20.18000:08:20.190 Sims I'm within range but I think one 00:08:26.69000:08:26.700 sim makes it perfect now we can try to 00:08:32.42000:08:32.430 shims but it looks like that side right 00:08:43.10000:08:43.110 here is just barely not touching because 00:08:47.06000:08:47.070 it's coming across the Sham too high so 00:08:50.06000:08:50.070 I think we'll be good you can see 00:08:53.51000:08:53.520 they're like I try and push it down and 00:08:55.22000:08:55.230 it's not wanting that Topsham on there 00:08:57.89000:08:57.900 so put that back perfect fit right there 00:09:03.38000:09:03.390 just one sim works so that's what I'm 00:09:06.47000:09:06.480 gonna go with on this cooler and then 00:09:09.26000:09:09.270 you have your little black rubber ring 00:09:11.39000:09:11.400 here and the best way to install this is 00:09:14.69000:09:14.700 to take this and put some grease on it 00:09:18.53000:09:18.540 and then put it on the block and when 00:09:22.88000:09:22.890 you go to install your old cooler then 00:09:26.35000:09:26.360 just see so yeah put some grease on this 00:09:32.35000:09:32.360 and just like that and then leave your 00:09:41.03000:09:41.040 bolts loose put your alignment tool in 00:09:46.16000:09:46.170 and then tighten in your four bolts down 00:09:49.58000:09:49.590 and then you can remove it and what I 00:09:52.43000:09:52.440 always do is I always you have the right 00:10:01.34000:10:01.350 alignment you will be able to put your 00:10:05.54000:10:05.550 OPR be in even though the new seal 00:10:11.67000:10:11.680 all the way so I just keep turning it by 00:10:18.81000:10:18.820 hand put it in the block if it is 00:10:21.60000:10:21.610 correctly aligned you will be able to 00:10:24.60000:10:24.610 just keep turning this until it goes all 00:10:31.19900:10:31.209 the way in and then you can lock it down 00:10:35.15000:10:35.160 so alright guys that's gonna do it for 00:10:37.80000:10:37.810 this episode I hope you guys enjoyed it 00:10:40.29000:10:40.300 and I hope it helps you the next time 00:10:42.63000:10:42.640 you go to install your old cooler 00:10:44.91000:10:44.920 housing and I'm gonna wrap this video up 00:10:48.24000:10:48.250 with some footage of the differences 00:10:50.73000:10:50.740 between the blocks that you will find 00:10:53.25000:10:53.260 between the early and late cars so until 00:10:56.25000:10:56.260 next time guys so here we have an early 00:10:59.13000:10:59.140 block and you can see the steel sleeve 00:11:01.47000:11:01.480 that is referred to in the factory 00:11:03.18000:11:03.190 workshop manual you will need a special 00:11:05.85000:11:05.860 tool to align the housings on the early 00:11:09.60000:11:09.610 blocks with this sleep and you can see 00:11:12.30000:11:12.310 here how the early one-piece seals 00:11:16.59000:11:16.600 against that sleeve and you can only use 00:11:20.60000:11:20.610 either the early 3-piece or the early 00:11:25.76900:11:25.779 one-piece with these blocks the later 00:11:28.86000:11:28.870 Opie RV will not work because the 00:11:33.81000:11:33.820 threads are longer and you end up just 00:11:36.92000:11:36.930 bottoming out here before it even gets 00:11:39.36000:11:39.370 threaded in and it's not gonna work 00:11:43.11000:11:43.120 anyway because this piston isn't sealing 00:11:46.41000:11:46.420 inside the sleeve as it should relieve 00:11:48.60000:11:48.610 pressure so 00:11:50.21000:11:50.220 it will not work and now we'll go on to 00:11:53.33000:11:53.340 a later block and show you the 00:11:55.73000:11:55.740 differences there so here you can see a 00:11:57.74000:11:57.750 later block and it does not have a steel 00:12:00.53000:12:00.540 sleeve the OPR V on the lighter cars 00:12:04.81000:12:04.820 actually go in until the seal pops in 00:12:08.27000:12:08.280 place and that's how it rests now if you 00:12:14.48000:12:14.490 were to take an early OPR V and slide it 00:12:18.35000:12:18.360 in there it's not gonna reach because 00:12:20.30000:12:20.310 the steel sleeve comes out to about 00:12:22.58000:12:22.590 right there 00:12:26.31000:12:26.32000:12:32.40000:12:32.410
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