Kiwi 928 S2

Nice one. I am also a new owner of a manual S2. And absolutely loving it.

Igaffz

Hi guys, I've been busy collecting parts my new project. Firstly though I needed to get the car out the rain as my 964 is in the garage, so I built this to keep her dry!


Next thing is the overdue timing belt. I'm currently half way through this job and couldn't have even attempted this without this forum and the excellent DIY threads. I just hope I can put it all back together!!
I checked the dizy caps last week and they looked very poor so I've bought two new caps and rotors plus eight spark plugs, I'll change these when I've finished the belt.
Next big job will be the sump gasket as its leaking badly!
Going to get her mechanically sound this year, then sort the interiour and body work next year.

More updates soon

Ian

Hilton

Good progress!

While you're doing the dist. caps and rotors, also change the belt that drives them.

Sump gasket isn't hard, just messy, and while you're doing it, plan to do engine mounts too. The common solution instead of the v. pricy Porsche ones is some Volvo mounts which are slightly taller, but also hydraulic and the same shape.

Igaffz

Hi Hilton, I've renewed the dizy drive belt on my 964 so that shouldn't be big problem.
I'm very happy to report I finished my belt and water pump on Sunday, I also partially rebuilt the tensioner. Apart from a squeaky belt that must need a bit more tension it all went well.
I'll change the dizy caps, rotor arms and plugs this weekend then it's checking for vacuum leaks to fix the constant hot air regardless of the temp selector position and the sump gasket, so I've got plenty of in at the deep end jobs to do!

Cheers
Ian

Igaffz

Hi chaps, changed the dizy caps, rotors and plugs on Saturday, progress is going well but I'm stumped and need help with my new problem. If I drive the car with the window up everything is normal but if I lower the window when I'm moving the smell of petrol is awful! If I stop and leave the engine running and try to find the leak the smell has gone? I've checked the car from front to back, there's never any petrol smell at the engine and the pipes arent leaking either? I've removed the cradle from the tank and checked the pump and filter and no leaks found. I did a search and found that it could be the Y connector at the charcoal filter but my 85 S2 dosent seem to have this? I'm stumped, you guys got any idea?

Cheers lads

Ian

Hilton

The smell is probably a broken (plastic) Y-connector in the aft end of the front right wing.

It joins the charcoal canister to the fuel tank ventilation system to reduce fuel vapour emissions - the plastic commonly fails. Its a cheap part, and a quick fix - just need to remove the wheel and wheel well liner, and its all there in front of you.

Igaffz

Hi Hilton, I removed the front right wing liner yesterday but there was no charcoal filter or Y connector only the window washer bottle?? There seemed to be only water pipes coming from the wash bottle? Could my model not have the charcoal canister? It's a 1985 S2.
There seems to be a seperate black plastic bottle in the rear right wheel arch next to the petrol tank? Not sure what that is?

Cheers
Ian

rbrtmchl

Igaffz,

Hilton is using Porsche standard when he refers to the front right wing. This is the passenger side for you in the UK (driver's side for me in the US). There are many threads on RL about this frequently broken Y connector causing the gasoline fumes that you are describing.

Igaffz

Dooooh, what an idiot, I forgot you guys put the wheel on the wrong side!! I'll strip out the passenger side arch liner tomorow and see if it's broken.

Cheers
Ian

bureau13

At least on the US cars, it's in the same general vicinity of the windshield washer bottle.

The hardest part was getting the old broken pieces out of the hoses. I had to cut the end off of one, fortunately it was long enough to still attach.

Hilton

No, its the driver's side in the UK (Right-hand drive), also called the off-side (as its the side furthest from the curb). Porsche convention is to call left/right as if you were seated in the driver's seat. Front-right is the driver's side on a RHD car.

Ian, its possible your car didn't have a charcoal canister from factory - but I thought it was standard for all LH-equipped cars, even those without cats (both my ex-UK 928's have the charcoal canister).

Obvious question - have you checked for fuel leaks? Jumper the fuel pump relay so the pump is running without the engine running, and go check all the fuel lines and unions for fuel.

Also check the top of the fuel tank - there's a plastic cap in the floor of the rear hatch on the right to get access - the gasket at the top of the fuel sender may be leaking.

Igaffz

Thought I'd update you on my fuel smell problem. It would appear I don't have a charcoal filter as there isn't one under the right hand wheel arch? Anyway I decided to drop the tank as the smell always seemed to be at the rear right wheel arch. Then I thought I'd remove the plastic cover at the front of the rear arch. That's when I found it! Behind the cover at the front of the recirculating tank there was a rubber pipe coming from the tank and bent round and zip tied in a loop. It looked like it had been blanked off with a bolt and clip and they'd rotted away letting the fuel smell escape. I couldn't work out where the pipe was supposed to go so I decided to blank it off again, seems to have done the trick but I'm sure the pipe should vent back into the tank or engine??

Also any ideas why my parkbrake light dosent work? I've checked the switch at the lever and it seems ok and it's not the bulb as it lights up when you turn on the ignition the goes out when I start the engine weather the park brakes on or not?

Many thanks
Ian

Igaffz

Hi guys, been trying to make some progress with my HVAC blowing hot air all the time problem. The blue valve at the brake booster checks out fine and I couldn't find any problems with the vacuum lines or connections. I removed the vacuum manifold at the centre console and checked for leaks, it appeared there may be a leak on the White line so I fitted a new heater control valve at the fire wall. A couple of the other lines lost a little bit of pressure but very slowly and a bit stop start, not steadily like a leak? I hoped I'd sorted the problem with the new heater control valve but unfortunately not. It still blows hot even if the levers all the way to the left? At one point there was a clunk behind the centre vent area and the blowers started blowing lovely cold air but as soon as I pushed it to hot and back to cold it stayed red hot?? I was planning to check all the vacuum lines again in the morning for leaks, any other ideas I could try?
How dose the heater control valve work? Should the valve be open when the heaters on hot and closed on cold or dose it not work like that?

Please help

Ian

Igaffz

Just to add my AC dosent work, the motor dosent kick in when turned on so suspect no gas, am I right in thinking this won't effect the heater control if it's not switched on? I've been Googleing all night but I think I'm more confused now!!
Could be internal or external temp sensors?
Mixer flap/motor?

Thanks
Ian

SteveG

Why google? You do know you can search here? Lots of threads on heater control and how to fix.