Many people have inquired
into whether the Turbo S auxiliary oil cooler (or any other brand for that
matter) can be installed as a DIY project. Well, if I can do it, just
about anyone can. Below is the Turbo S Aux Oil Cooler kit as ordered from
Gert at www.carnewal.com. There are several online vendors that sell this
kit. This is the OEM oil cooler that Porsche used on the 993 Twin Turbo S.
Because of this, it fits very nicely into the 993TT and I would assume any
wide body 993. This is also the auxiliary oil cooler used by Andial on all
of their high HP 993TT upgrades (at least per their rennlist posts).
Many people prefer larger
auxiliary oil coolers, such as the Cargraphics unit below, as they provide
even more cooling capacity. The downside to these units is that they will
fully block your AC condenser, thereby limiting your AC’s effectiveness.
In any event, I believe these instructions should apply to the larger oil
coolers as well.
Jack up the front of the car
and put it on jack stands. See
http://p-car.com/diy/jack/ for instructions on this step.
Remove both front tires and
then remove the front bumper cover. See
for detailed instructions.
In this step you will replace
the oil cooler vent cover with the new cover that allows the new oil lines
to be run from the existing cooler to the auxiliary cooler.
This “vent cover” (I am not
sure what the actual part is called) sits on top of the oil cooler and
helps to direct the air coming in the front air duct through the oil
cooler. Here is a picture looking at this from the front of the car.
Once you have the bumper
cover and wheels off you will have easy access to the oil cooler, which is
located in front of the passenger side wheel well.
The first thing I did was to
remove the rear vent cover so that I had better access to the oil cooler.
Here is the same area with that panel removed.
Once this rear vent cover was
removed, I then reached in and removed the screws holding the upper vent
cover in place. At this point there are only a few bolts holding the oil
cooler to its mounting bracket, so I removed these as well. This enabled
me to have better access to the oil line connections later. I then went
ahead and attached the new upper vent cover (it attached in all the same
places as the original cover). I set the new oil lines into the new vent
opening so that I felt like I was making some progress. With steps 1 –3
done, I think I took a long break.
In this step, you will you
will remove the temperature sensor bracket from the bumper. These sensors
are located on the driver’s side of the front bumper as noted in the photo
In order to move these
sensors, you need to drill out the 2 rivets that hold them in place. The
brackets sits on top of the bumper, so I drilled the rivets out from the
bottom. Once the rivets are removed the bracket and sensors can be set
aside while you work on step 5.
It is now time to install the
auxiliary oil cooler bracket and oil cooler. In order to install the
bracket it is necessary to drill 2 holes in the bumper to match the bolts
provided. Optimally, you will position the bracket so that the oil cooler
sits squarely in the bumper duct. Once this bracket is attached, connect
the auxiliary oil cooler to the bracket using the nuts and bolts
Reattach the temperature
sensor bracket as far as possible to the left. Simply mark new holes,
drill them out and reattached the bracket with a rivet gun. Once the
bracket is in place, be sure to plug the sensors back in.
It is now time to install the
oil line brackets. This requires that you drill 2 holes in the bumper lip
as shown below. Note that at this point I have dry fitted the oil lines to
the auxiliary cooler. This is just so that I can make sure everything fits
correctly and I can attach the oil line brackets. The oil lines are the
It is now time to plumb in
the new lines. I put a box under the oil cooler to catch any oil, but very
little dripped out. I also placed the ends of the auxiliary lines in a
bucket for the same reason.
Remember from Step 3 that the
main oil cooler is hanging free. Disconnect the rear facing oil line. I
used a large crescent wrench and an open-end box wrench to disconnect the
line (you need 2 wrenches – one for the female oil line connecter and one
for the male oil cooler connecter). Once this line is free, you can attach
the curved auxiliary line to the main oil cooler.
Please Note: the new oil
lines come with plastic plugs in them. You need to remove these plugs
before final attachment or the oil will not flow resulting in serious
Now take the line that was
previously attached to the main cooler and mate it with the other line
going to the auxiliary cooler. Make sure these connections are nice and
Now attach the other ends of
the lines to the auxiliary cooler, being sure to remove the plastic plugs.