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- Cleaned up the licence plate light circuit connections and replaced both dead lamps.
- Installed a new headlight motor relay cover.. Note: For anyone trying to do this, please make sure the connector goes into the motor correctly or you WILL have a disaster on your hands.
- The next project was twofold: Install all new vacuum lines and (while I'm in there) replace the AOS O-Rings. The intake manifold came off without any hassle but removing those intake gaskets was quite a chore. I think I spent at least 4 hours (carefully) cleaning those surfaces.
Engine bay prior to the hammer...
Fuel rail & intake manifold off:
A huge shout out to Steve Manfre, from 944Online, for sending me this all inclusive vacuum hose kit. It contains everything you need, including all new hoses, clamps,junctions, intake bolts, gaskets and that incredibly expensive J-Boot that mounts under the manifold. The kit is new and made of polyurethane.
Lots-O-Dirt:
- Starting to come back together:
Of course, what's a project without a mishap? I managed to break the booster check valve while attempting to remove the vacuum hose. That bugger is pricey for a little piece of plastic...
That new double headed J-hose from 944online is nice. I don't think it was available last year when I bought the genuine hose from Porsche. It's pretty amazing it is even available from the dealer but the cost was high for what it is at about 100 dollars. What did you do with the venturi: leave it alone, replace, or delete? I see the idle valve on your bench. I wish I had cleaned and tested mine when I had the intake off last year. I was pretty thorough but missed that. If you're sending your injectors out for cleaning I had a good experience with Marren in Connecticut, but I'd guess you already have a preferred vendor for that service.
Patrick- Good write up and by coincidence I’m going through almost the exact items on my 86 NA. The area around my air oil separator is especially oily. Is it typical to just replace the o-rings or is the canister considered a replacement item? Thanks!
Been waiting on parts (and really busy at work) so didn't accomplish too much this week. However, I had some time today to keep poking around areas and start repairing a couple minor issues:
1. Only one cooling fan would turn on; a replacement relay cured that!
2. While disassembling the engine last week, I found this boogered up hose. It was also replaced today.
3. This issue was fun!! The radiator drain plug snapped while I was gently screwing it in. The entire unit had to come out in order to tilt it over and allow the piece to fall out of the large upper hose port. Anyway, it's all all back in place with a newly installed drain plug.
4. Removed the driver's seat to start shampooing that side of the cabin: (Before)
After:
I discovered this while removing the seat:
As with my other car (The Beastie), I will have to perform a little surgery and drill through the pan - Install M8 bolts with fender washers. This is actually a Porsche TSB for these early models.
Puttered around a little yesterday... While cleaning up/verifying the rear sway bar torque settings, I found this - every bolt was loose on both axles.
Just an FYI; Routinely check these torque settings (early cars are 31 ft/lbs, I'm not certain about later models). I always grab my torque wrench prior to any road trip.
12-31-2022, 02:04 AM
