NelaK

I finally got some time to take a look at my 924S after a loooong time and noticed that it is leaking quite badly from the front of the cam tower (where it seals with the distributor I guess?) and I have oil going onto the exhaust manifold and into the timing belt cover too I believe.

Anyways - I guess its time for a bunch of maintenance on my 924. What are all the while you're in there type things I should address and what parts should I just order? I'm building my shopping list based off the parts list on Clark's Garage for now.

- Timing belt
- Pulleys
- Water pump
- Cam seals
- Distributor/rotor?
- Valve cover gasket?

tempest411

I had the same problem. It was this little rubber seal between the head and the top/rear distributor cap mount. I did as you have planned, and also pulled the head for a rebuild, replaced every single hose, replaced every sensor, new water pump and did the rod bearings as well. Just to make sure it would be reliable.

jeyjey

I wouldn't bother with the cam tower gasket unless it's leaking.

I would do the distributor and rotor.

And if it's not already been done, I'd put an offset cam key in (or an adjustable cam gear).

16again2009

Balance shaft seals and belt.

NelaK

Can you elaborate more on that? Where would I get it? Googling reveals a bunch of people talking about 928s and 944's but nothing for the 924s

NelaK

I'm tempted to go down the same route as you. Pull the engine before winter sets in and then rebuild it over the winter. My car has somewhere near 500,000 miles now I think and its definitely showing its age. The motor still runs well asides from an oil leak here or there and probably a few minor vacuum leaks. There would be no increase in value for the car for all the work and parts but I've never torn down and rebuilt an engine before (the closest was replacing some valve stem seals on a BMW N62) so it could be a valuable learning experience on a car that is near the end of its life anyways?

How much did all of it end up costing you in money and time?

jeyjey

924S is the same engine as the 944, so the cam advance keys fit the same.

Gage

This makes for a great project. There is two to three thousand dollars of parts and machine work to reassemble one from the shortblock, leaving pistons and crank in place.

tempest411

If you can tear down an N62 to replace the valve stem seals the Porsche 2.5 will be a walk in the park.

NelaK

I think I'm going to plan to pull the engine and transmission this weekend. I don't really have a full plan yet but the list of things the car needs is just piling up and they'll all be easier with the engine out.

One thing I was curious about though is the transmission. My synchros are pretty badly worn on 1-2 and 3-2. I know there's companies that will rebuild them in the US but shipping my transmission from a remote part of Canada and across the continent twice will be absurdly expensive. Is it possible to DIY rebuild these transmissions? (Keeping in mind that I have zero experience with transmissions). Or even order the parts and expect a transmission rebuilder closer to me to be able to get it done? I'm assuming that at this point every 924/944 transmission will be in similar condition so trying to buy a used one is not really worth the hassle?