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Turns out 1/4 inch is too small for plugging the test port fittings on the exhaust. I've ordered two other sizes and will post which one fits best. The only things stopping me from starting the car are two little ball bearings. Maybe they don't matter that much...but maybe cause a false reading by the O2 sensor.
Final tasks completed today:
Ground a nickel to block the air pump fitting to the cats.
Added coolant and checked for leaks.
Changed the oil (Didn't notice any coolant in the oil...which is good news)
Removed the fuel pump relay and jumped it. Ran the pump for about 20 minutes while looking, sniffing, and listening (sounds like a small stream flowing under the hood). Left pieces of paper towel under fittings. No leaks. Also checked the fuel injectors at the fuel rail. No leaks.
Aside from the ball bearings to plug the sample ports I still have the front right wheel well liner and wheel to put back. Too soon to feel relief...I installed aircleaner and intake tubes to prevent any of the commonly reported odd running when they are off.
[*]Removed the fuel pump relay and jumped it. Ran the pump for about 20 minutes while looking, sniffing, and listening (sounds like a small stream flowing under the hood). Left pieces of paper towel under fittings. No leaks. Also checked the fuel injectors at the fuel rail. No leaks.
The ball bearings arrived early. Turned out even a 3/8th inch ball didn't stand out enough to be pressed by the sampling tube cap fitting when fully threaded. I have some miscellaneous Porsche small bolts, nuts, and washers in a bin and found two washers that fit perfectly inside the cap fitting. Perfect. Seems this is just one of those things varies from car to car.
Car started right up but stumbled a bit at first. It idled a rough for less than a minute, then just a bit of stumbling idle, and finally after running for about 15 minutes it warmed up and idled more smoothly. By 20 minutes the fans started cycling and the idle had settled to 600 rpm.
Here's a short video. Planning to drive it to Camp928. If you hear something odd, let me know
Congrats Jon.
Outstanding job.
Always reassuring when you hear the engine running perfectly well like yours after a major refresh like this.
See you next weekend.
Chart, hope yours will be ready too.
It could not be in better hands right now than Dave's.
I would love to see your car.
Good luck.
It's a great feeling when you fire it up; especially after long-term projects. Great job! I've been told real men put the belly pans on before the first test drive <lol>
I've been told real men put the belly pans on before the first test drive <lol>
LOL thats asking for trouble.
Jon Glad its back to running, now go for a drive.
NOTE the first start stumble is due to the computer relearning the parameters,
get a few full throttle to the floor cycles on your drive, to assist in the computer learning.
make sure the heater is on hot ,
drive it then park it and let it cool off then top up the coolant.
To all - Your support and congratulations mean a lot. Only those who've done these tasks or who are contemplating doing them realize this is not something we engage in casually. For the first timer there are many anxious moments along the way. The only tasks we can assure are done with the quality and care we want are those we do ourself or with the aide or service of others in our community who have gone there before us - some with the wisdom from doing these tasks many times. Looking forward to meeting folks at Camp 928.
Stan - thanks for reminding me to open up the heater valve!
Last edited by Captain_Slow; 06-15-2018 at 07:16 AM.
Two days after buttoning up the engine I made the trip to Curt's place in the Adirondacks - about 17 hours round trip. I honestly expected to discover some kind of problem, at least an air or vacuum leak. I was nervous after reading about a water pump failure stopping another rennlister from driving his 928 to the event. So the day before departure I took the S4 out for a vigorous 50 mile test drive, including a couple long mountain climbs while accelerating most of the way. It did fine so I pushed my fear aside and asked myself out loud "Do I see any reason to not drive this car to Camp928?" The answer was a simple "No". So I packed my stuff into the 928, including a care package of fluids and tools I might need.
The trip went extremely well. The scenery was amazing on I-81 north of Harrisburg, same for I-88 and I-87. The roads need work. The joints between the concrete sections were almost like driving on railroad ties at times (staying in the left lane helped). The car on the other hand really impressed me. This was the first long-distance trip I've taken in a 928. When the road was smooth it was really comfortable - especially the seats, driving position, and forward visibility. The abundant power and torque at 70-75 mph was impressive and made passing easy - no downshifting, just strong and easy acceleration. I was most impressed by how cool the engine remained. Whether running just the blower or the AC the coolant temperature hovered just above or below the first line on the temperature gauge (on the return trip outside temperature was 90 with high humidity). Throughout the drive up and back home my confidence in the car (or in my intake refresh job) increased steadily. I feel a bit lucky that there were zero hiccups or worse on this trip - a nice reward after about 5 months of slow and steady progress on the refresh.
The needle never moved more than half the width of the needle.
Driving and enjoying the car and the results of the top-end refresh. On the way home from Camp928
Last edited by Captain_Slow; 06-21-2018 at 02:48 PM.
The most excellent update. I (somehow) am breathing a huge sigh of relief on your behalf. It's wild how vested we sometimes get in OPP (other people's projects) but it's probably a reflection of our dedication to these cars and the bond it creates between us. Kudos, congrats and good job my man. This trip and hopefully thousands of additional unfettered miles will be a satisfactory reward for all of the headaches, sweaty nights, and sore morning-afters. Well done. Vicariously Josh
Thanks, Josh! Your Ladybug project was one for the ages. The connection to your father's Porsche and how you did many things in an original and different way - a very cool project. I must have thought of your project a dozen times - admittedly sometimes simply to remind myself I wasn't tearing things down as far as you did on Ladybug! We talked about wrapping a car at Camp928 and your thread came up in that conversation.
Last edited by Captain_Slow; 06-21-2018 at 05:19 PM.
06-10-2018, 09:41 PM
All I need are properly sized ball bearings...
Turns out 1/4 inch is too small for plugging the test port fittings on the exhaust. I've ordered two other sizes and will post which one fits best. The only things stopping me from starting the car are two little ball bearings. Maybe they don't matter that much...but maybe cause a false reading by the O2 sensor.
