86 951 Driver

Any pics of the setup working?

Jagbuff

Unfortunately progress has been erratic due to family issues which included a trip back across the pond. The light setup is completed and functional with the modules fitting as such



Shot of the lights on (hard to tell b/c of lighting)

Jagbuff

I tackled fixing the rust under and around the air box. As this is out of sight, I didn't bother will perfect finish, just good surface prep, rust treatment, etching primer and single stage color

Jagbuff

CV joint out to replace the torn boot



New CV boot is in place.



While there, I decided to replace the shifting system with a short shifter that one of the listers built...



...but luck is not on my side and the main bolt broke so I will have to drill out

Jagbuff

Decided I need a fuel shower so replaced the fuel filter



The injectors came back all cleaned and balanced from RC engineering - highly recommend the service. They provide a before and after spec sheet - two were originally dripping, all had poor spray.



They also repaint them - pretty!



As I am installing 18" Turbo twist wheels, I followed the recommendation of the list and replaced the front suspension bushings. The old ones were starting to fall apart



New ones installed!

Jagbuff

Front suspension reassembled with M030 Konis, new rotors/pads, SS lines and repainted calipers



Same for the rears



Alternator cooling hose was destroyed



New one in place



While there noticed the steering rack boot was damaged



Replaced was new one

Jagbuff

Cam tensioner pads replaced



I also replaced the came chain and seals - I have to say that I hate those 12 point bolts....



Bearing and cams are in very good shape - comforting!



Waterpump (POS - more about that later) and timing belt in place



While I was very cautious about cam location, you can NEVER be sure that the prior guy didn't muck things up on the last belt change - trust but verify!! This is my timing set up, had to improvise a little



TDC verified per WSM and perfect match on the lift for the 3.0L engine (0.75mm)



Balance belt installed, all bearing seals have been replaced



New starter in place...



Cam cover is repainted wrinkle black, new rotor and cap, new hoses etc... Ready for the BIG moment !!!

sydneyman

wow, you're really going to town! excellent work all around!

Jagbuff

Anyone who has worked on cars is always anxious about that first turn of the key. After filling the cooling system and pressurizing the fuel system, I crank the motor and after a couple turns it catches and settles to a perfect idle (still think the starter motor sounds like a truck...) with good oil pressure.

All is good and I start checking the systems for any leaks, oil, fuel, coolant....well coolant is dripping slowly under the engine next to the power steering pump. I stop the engine and check for any hose leaks...everything is fine and tight. The dripping continues and worsen as I pressurize the system....NOT good, I continue to explore and determine that it appears to come from the waterpump area. WTF, did I forget to tighten something?? Only option is to take the back cover off which means removing the belts etc.... Hardly a joyous moment.

Soooo, after 30 minutes I am able to get to the source, the culprit is the water pump bearing that is leaking, the new refurbished water pump that I decided to replace as a preventive measure (even though the other look quite new see prior posts) is leaking significantly.

NOT a good day!!!!

Charlie944

SOB! I am so sorry that a DOA water pump has plagued your progress! Somewhere I have an image of cuts you can make to your rear timing cover so that you can pull just the water pump and not have to remove the balance shaft sprockets and crank pulley/gear. Save a ton of time.

Josh B

Man - that sucks. I always dread that first start too! Hope it isn't too much trouble replacing that pump...

Thanks for all the pics - very enjoyable thread to read!

Jagbuff

...So I called the nice folks at AA to ask for a replacement pump. The pump arrives but it is not the correct one - WTF!!



Needless to say I am getting a little frustrated with this part of the project, fortunately Leo is able to help me out the following day and overnights the correct pump - what a thing of beauty



In the interim I tackle the shifter which decides to put up a fight and shear off the main bolt...fortunately nothing a drill, a tap and patience can't fix



The new shifter made by one of the listers being installed -



After it is installed, the shifter still has sideways play around neutral (about 3/4") I decide to remove the shifter **** cover and explore - was going to replace the plastic cup anyways. I appears that the connection between the shifter and the main bar has play from wear. Shifter is fine so I decide to to drill out the main bar and machine a very thin brass bushing (oil impregnated) to take up the play - this was not an easy job in situ but the result was almost Miata-like Unfortunately I didn't document with pics

Water pump is installed, system is pressure tested and no leaks (note the missing front fender...more on that at another time).



Car starts right up and runs flawlessly. Still need to attache undertray but will put a few miles on to assure allis ok. Couple of garage shots - excuse the dirty floor - will post driving impression under other thread.

redmund

It's amazing what money, time, and a bit of skill can do for a car. That looks awesome, great work.

JoDa

I am thoroughly impressed by your attitude and positivity here Jagbuff. Being misled through a deal like this, would throw a lot of people off before the project even starts. Kudos to you!

Being a S2 owner myself, I find this thread both inspirational and educational (great pictures!) and looking forward to any updates.

Now then, for me it is all about finding 944 time between two small kids, a dog, full time job and maintaining a healthy relationship with the missus :-) (And it doesn’t help being wintertime in Norway with subzero temperatures for about 5 months a year either…)
How the heck do you find the time? ;-)

Regards, John

Jagbuff

THX, staying positive helps make the experience more pleasant!!...I understand the challenges having two daughters myself who are growing fast and a very busy work life. Fortunately I have an extremely understanding wife who lets me play with cars as a way to reduce stress and a good set of tools - being somewhat of a type A person also forces me to fill every minute of my day (and night) with some sort of activity so progress is usually pretty good (although this project was interrupted by two trips back to France due to family issues). BTW, stay warm - working in the cold in no fun - I'll take 40-41C for months at a time (Texas summers) over freezing!