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Stayin’ alive – the ongoing story of my 1987 924S survivor
I am pulling together several threads on my 924S and I will add others in the future. Hopefully this will be of use to others… now that I have pulled the list of threads together I realize that I have done a lot of minor PITA repairs that are a bit obscure.
This picture is the day it arrived, parked beside our house that I was doing major renovations on.
First major project was the timing belt, water pump, balance belt, front balance shaft seals etc. https://rennlist.com/forums/rennlist...lt-change.html
This was in the fall of 2012, I changed the belts again in 2017 and the balance shaft seals are still good, no oil behind the timing belt covers.
The old hood liner was disintegrating onto the engine, so I found a replacement… https://rennlist.com/forums/924-931-...e-abstain.html
This repair seems to have held up well, I had to reglue one small area that was not properly stuck down.
I had depowered my power steering rack but really didn’t like it, so decided to rebuild a rack to reinstall it powered. I didn’t want to take the car off the road while doing the rebuild and I didn’t really want to clean out all of that grease that I put into the rack when I depowered it, so I went looking for a rack to rebuild. https://rennlist.com/forums/924-931-...ring-rack.html
Originally my objective was to replace my 5-year old timing and balance belts and install my rebuilt power steering rack, but decided to check the vacuum hoses under the intake manifold and change the fuel lines while the car is off the road with the front end up in the air.
While replacing the belts I took the opportunity to verify the water pump, the gears and the rollers, everything was good and no oil leaks in the area protected by the covers.
I removed the fuel rail and intake manifold and was happy to find all the various vacuum lines and fittings in great shape, I think the previous owner must have changed them while working on the head some years ago.
Shortly after buying the 924S the wiper motor stopped working. I took it apart, cleaned and greased it and got it working again… but it made a horrible growling noise. So using http://forums.pelicanparts.com/porsc...eanimated.html
… and from the 928 forum... https://rennlist.com/forums/928-foru...-overhaul.html
I disassembled the motor and replaced the bearing between the motor and the worm gear. The hardest part was getting the bearing off the motor’s shaft and getting the new bearing on. Once it was all back together and installed it ran quite nicely.
Winter has slowed down the reassembly process, but now that the garage is back to slightly above freezing I have started to work on the 924S again. I decided to change the oil cooler seals before going any further... https://rennlist.com/forums/924-931-...l#post14863915
Last edited by elgy; 06-06-2018 at 09:27 AM.
Reason: spelling
The 924S has been back on the road for a couple of weeks now and all seems to be fine. The most important work done:
-installed the rebuilt power steering rack and pump
-new timing and balance belts
-oil cooler seals
-throttle body rebuilt with Arnnworx kit
-wiper motor rebuilt
-replaced thermo fan switch (again)
-new plugs
-checked vacuum lines
-new under hood fuel lines and fuel rail jumper line
-new AOS seals
-new air filter
-new accessory belts
-changed engine oil and filter, coolant and transmission oil
It sure is nice to have the power steering back! I have been checking for leaks daily and so far I haven't found anything amiss, in fact the driveway under the car is the cleanest it has ever been.
The only problem is an annoying vibration at idle, especially when it is cold. Is this a sign that my cheapo engine mounts are nearing the end of their lives? The engine is not bouncing around at idle like it did when I bought it, so the mounts are not totally degraded.
Last edited by elgy; 10-12-2018 at 09:16 AM.
Reason: grammar
Bookmarked.
Thanks for the information.
You might check the fuel injectors-flush and reseal. They may be sticking.
Usually the mounts. Sunset Porsche has the OEM Porsche for $ 198 each. Tip: spray the top of the mount to slide in easier and not cut the rubber. (from Timmy! Comeau racing San Diego.)
I have not had lasting success with Meyle or URO.
John
... the only problem is an annoying vibration at idle, especially when it is cold. Is this a sign that my cheapo engine mounts are nearing the end of their lives? The engine is not bouncing around at idle like it did when I bought it, so the mounts are not totally degraded.
Well, my bad... I finally checked the balance shaft alignment (I was sure that I had installed the belt correctly) and found that the lower shaft was about 180 degrees off. Since the upper belt cover is still off it was an easy fix working from underneath. (Love my Quickjacks!)
On first startup it was back to normal... still have to do a road test.
Except that the problem turned out to not be the clutch... this is explained in the above thread where I also conclude that the real culprit was the transmission mounts. I rebuilt them, the process is documented here: https://rennlist.com/forums/924-931-...l#post15421995
I will only know if the problem is corrected when I get it back on the road, soon I hope.
Last edited by elgy; 08-12-2019 at 08:39 AM.
Reason: spelling
For those that have not read the updated thread in the above post, the rebuilt transmission mounts did not work, well they didn't work for long, so I ended up installing used OEM mounts and I seem to have finally solved the problem.
My horn had not been working and while working on that problem I also changed my ignition switch which intermittently refused to turn. https://rennlist.com/forums/924-931-...l#post16035809
I have sold the 924S so this is the end of this thread, I hope that it will continue to be of use to others. I will drop in to visit from time to time and will still be active on the 986 Boxster and 928 forums.
11-03-2017, 01:22 AM
Stayin’ alive – the ongoing story of my 1987 924S survivor
Since the upper belt cover is still off it was an easy fix working from underneath. (Love my Quickjacks!)