In our last segment of Project 987.2 Cayman, to prevent the dreaded on track overheating engine and transmission limp mode, we greatly increased our engine’s cooling capability by switching over to all-aluminum, bigger, and more efficient CSF radiators with a radiator mounting kit and nose vent kit by Rennline. Now it was time to complete our overheating countermeasures by adding high capacity oil pans for the 9A1 engine and PDK transmission along with bigger oil coolers for the engine, PDK transmission, and power steering system from a subsidiary of LN Engineering, Bilt Racing Services or BRS.
Read all the build details of Project Cayman here.
The billet BRS 9A1 oil pan is CNC machined from tough 6061 T6 aluminum alloy making it much stronger than the stock cast aluminum pan. It holds 2.5 more quarts and stock and relocates the OEM oik sensor so it reads the oil level accurately. No other aftermarket pan for the 9A1 does this which is important because Porsche does not have a dipstick and relies on the sensor to determine oil level accurately. The BRS pan also has fins machined into the bottom for more stiffness and better heat dissipation as well,
These machined bosses are to allow for the installing of the OEM pan baffling which unlike the M96 engine the 9A1 proceeds, are actually pretty effective. With the new pan, the oil capacity is increased to 10 quarts and the oil temps generally drop 40 degrees on the track from the limp home temperature of 300 degrees to 260. Ideally, oil temp should not really exceed 24-250 degrees so we are still going to need to address this.
The stock Cayman has a tiny oil to water oil cooler for the engine oil. We will be replacing it with a huge BRS oil cooler that is at least 2X bigger. It looks like the unit that is on 991 cup cars or the GT3 RS.
We will be replacing the stock plastic PDK pan with a BRS billet pan. Like the engine oil pan, the BRS PDK pan is CNC machined out of 6061 T6 billet aluminum which is way stronger than the stock plastic part. The pan has cooling fins machined on the bottom surface. The pan has a quart greater capacity than stock as well.
10 comments
Do you know if both the BRS side mount cooler and the BGB cooler can be installed? Or do they both cool the same (clutch?) oil?
One cools the tranny and the other the differential. Since we are not running a LSD yet, I didn’t think we needed a cooler after talking to guys who race these cars.
If you were to run an LSD, which LSD, and what cooler would you be exploring to use?
Probably a Setrab with an electric pump.
How did the intake manifold fit? It doesn’t seem like there is enough room for the larger oil heat exchanger. Also how far does the oil pan hang down front to rear?
Perfectly.
Great series on a great car. I’d love to see some before and after temperature data of the engine oil, pdk, and coolant system after all this work. I’d like to lower my own temperatures but it’s hard to know how much needs to be done to achieve reasonable temperatures.
We didn’t take any before but these cars are known to go into limp mode in just a few laps with a fast driver due to the PDK overheating. Ford Factory driver, Billy Johnson drove the car for a full session on a hot day with no issues, tuning a 1:57 at Buttonwillow.
Now that it’s been a couple years, how is the cooling on the 987. 2 working out on the track? I’m considering buying a 987.2 Cayman S and my only major concerns are the cooling and reliability of the PDK on the track (which I feel is related to keeping it cool)
Very well, is good even in hot weather.