sboxstergirl

Well I have good news and a major relief at least for the wallet..... I removed the small hose from the oil cooler and the milky oil/coolant mix began seeping from the oil cooler. I removed the oil cooler, poored a soapy water solution into the coolant ports and applied 60 psi air pressure to the oil passages. Bubbles galore! I will try and send pictures and a small video if possible. Does anyone make a retrofit cooler or larger more efficeient cooler to replace the factory cooler? I may make a block adapter and add an external cooler to keep the oil cooler. Please let me know if there is a company with such an adapter and cooler. Thank all of you that replied! :renntech: Now it's time to get busy and clean up the mess. :)

Guys, just to confirm there was no oil added to the cooling system by mistake. The issue is occuring internally inside the engine. :rolleyes: Keep me posted with your thoughts. Thanks!

Brad and JFP- Thanks for the thoughts and here is current the situation: -There is definitely milky substance in the coolant tank as oil mixed in the cooling system. Majority of fluid was oil. In other words no coolant in the crankcase but crankcase only had 3 quarts of oil when I drained it. - I used a wet/dry vacuum to extract the oil/coolant mix from the coolant tank and extracted several quarts as the tank began to overflow with the engine running and cap off. This is the reason I'm thinking the oil cooler or a pressure fed passage is allowing oil to enter the cooling system. Oil pressure is higher and overpowering the cooling system. If both sytems were equal pressure I'm sure I would have found the crankcase mixed with coolant too. -Dye is a good idea and I do have access to dye. -I am going to pressurize the oil galleries via oil pressure sending unit passage and pull the coolant hoses to expansion tank and see if there is pressure in the cooling system. If there is I will need to follow the hose back to the engine to determine where the leak is. - Is it possible for the oil cooler or head gasket to leak into the cooling system? - The engine runs normal and I'm afraid to run it for any length of time as oil leak seems to be constant and fairly large. I am still looking for a diagram of oil and coolant passages to see if there are any passages close to each other. Do the expansion plugs in the heads seal coolant or oil? I will keep everyone posted after I run my next test. Thanks for your suggestions and keep them coming! :D

well, I had a chance to go out and drain the oil and no signs of coolant in the oil. I also pressurized the cooling system and it is not leaking into the crankcase. Does anyone have an oil passage and coolant passage diagram? Any other thoughts were the oil could be coming from? Head gasket? Cracked or damaged cylinder? What other components share oil/coolant that would be pressurized by oil or possibly combustion? Are any of the cylinders close to the oil passage or coolant passages? I really would like to determine where the root cause is prior to removing the engine. I may pressurize the oil passage and see if I can determine where the leak is. Please respond if you have something that comes to mind. Thanks again! :huh:

Has anyone experienced coolant expansion tank on a 99 Boxster with a 2.5L engine filling with engine oil? It appears to be a pretty severe concern as the coolant tank is completely full of oil and the oil level is low. If the engine is started, oil will begin flowing out of coolant tank as it appears to be pressure fed. There is no smoke from the exhaust. Is there anything common here? Head gasket, oil cooler, cylinder cracked, etc... I don't see any coolant on the oil dipstick, just oil in the coolant tank but I have not drained the oil yet.... I will perform further diagnostics to try and locate concern. Does anyone have a schematic of the coolant and oil passages in this engine? Please let me know if you have experienced this concern and what you did to resolve it. Thanks! :o