Evening, about a week ago I had planned to take the car somewhere and decided to check the fluid levels before going and found coolant to be low and signs of mayo in the header tank. Having had a few issues with the car lately I had the hump but decided to pm Iain (demort) as he's best placed to offer an opinion on my latest issue.
Iain's thoughts are the oil cooler has failed as there is only a small amount of oil in the coolant and the oil is completely clean. I read around online and found everyone describing the job as very difficult to do with the engine in situ. Friday night the wife had to work late so I decided to have a look at the job and emailed Iain some pictures of my findings and he suggested I make a post so others can see what's involved and share my opinions on the job.
Below are a series of photo's I took during the job
that's what I discovered after topping the coolant up and leaving it a short while, there's very little oil in there but enough that it's discolored the fresh pink coolant already.
managed to snap the final bolt for the plastic upper manifold on the drivers side as you can see there's plenty of it left to work on I'm sure a few days soaked in plusgas and 2 nuts locked together will remove it. You can also see the oil cooler clearly.
Iain assures me the amount of oil in the various components above is a normal amount, I decided to remove the left hand upper plastic manifold too as I already had the alternator out to replace the regulator.
the above is a vacuum operated inlet changeover valve, the valve feels fairly seized up and is supposed to be connected to the stub in the bottom picture and isn't so someones been in here before me.
turns out it is the original '97 oil cooler still fitted, and the new one by the same manufacturer but not from an opc.
Now regards the job itself everything I read described it as a horror story but in truth all of the above took me about 2 hours including dodging the rain, a quick run down of the job goes
disconnect battery earth terminal
release aux belt tensioner and slip off belt
remove 3 bolts securing a/c compressor (rear bolt is awkward but you can get a socket and extension between the runners on the plastic manifold pull out and position near engine mount)
remove alternator (2 bolts plus wiring)
use a syringe and hose to remove fluid from power steering reservoir, remove reservoir (1 bolt, 1 quarter turn connection)
remove throttle body (4 bolts, unhook cable)
disconnect o2 sensor wiring
use trolley jack to support engine remove bottom nut off both engine mounts then lower engine with jack until you can get your hands to the rear jubilee clips
loosen jubilee clips holding crossover pipes between manifolds.
remove drivers side upper plastic manifold (6 bolts)
remove centre crossover pipes
remove passenger upper plastic manifold
all of the above requires very little in the way of tools or mechanical prowess, below is a picture of the tools I used except for the jack and a 1/2" extension bar and a 15mm socket
that's a £10 halfords 1/4" socket set, a 1/2" ratchet with 18mm socket, a 24mm socket and a pair of waterpump pliers so probably £35 worth of tools, so there's no reason why anyone couldn't do this job i'm now just waiting on some new o rings for the oil cooler and i'll get the new one fitted and see where we are
Chris
Iain's thoughts are the oil cooler has failed as there is only a small amount of oil in the coolant and the oil is completely clean. I read around online and found everyone describing the job as very difficult to do with the engine in situ. Friday night the wife had to work late so I decided to have a look at the job and emailed Iain some pictures of my findings and he suggested I make a post so others can see what's involved and share my opinions on the job.
Below are a series of photo's I took during the job
that's what I discovered after topping the coolant up and leaving it a short while, there's very little oil in there but enough that it's discolored the fresh pink coolant already.
managed to snap the final bolt for the plastic upper manifold on the drivers side as you can see there's plenty of it left to work on I'm sure a few days soaked in plusgas and 2 nuts locked together will remove it. You can also see the oil cooler clearly.
Iain assures me the amount of oil in the various components above is a normal amount, I decided to remove the left hand upper plastic manifold too as I already had the alternator out to replace the regulator.
the above is a vacuum operated inlet changeover valve, the valve feels fairly seized up and is supposed to be connected to the stub in the bottom picture and isn't so someones been in here before me.
turns out it is the original '97 oil cooler still fitted, and the new one by the same manufacturer but not from an opc.
Now regards the job itself everything I read described it as a horror story but in truth all of the above took me about 2 hours including dodging the rain, a quick run down of the job goes
disconnect battery earth terminal
release aux belt tensioner and slip off belt
remove 3 bolts securing a/c compressor (rear bolt is awkward but you can get a socket and extension between the runners on the plastic manifold pull out and position near engine mount)
remove alternator (2 bolts plus wiring)
use a syringe and hose to remove fluid from power steering reservoir, remove reservoir (1 bolt, 1 quarter turn connection)
remove throttle body (4 bolts, unhook cable)
disconnect o2 sensor wiring
use trolley jack to support engine remove bottom nut off both engine mounts then lower engine with jack until you can get your hands to the rear jubilee clips
loosen jubilee clips holding crossover pipes between manifolds.
remove drivers side upper plastic manifold (6 bolts)
remove centre crossover pipes
remove passenger upper plastic manifold
all of the above requires very little in the way of tools or mechanical prowess, below is a picture of the tools I used except for the jack and a 1/2" extension bar and a 15mm socket
that's a £10 halfords 1/4" socket set, a 1/2" ratchet with 18mm socket, a 24mm socket and a pair of waterpump pliers so probably £35 worth of tools, so there's no reason why anyone couldn't do this job i'm now just waiting on some new o rings for the oil cooler and i'll get the new one fitted and see where we are
Chris