Compiling Comprehensive List of Maintenance
04-30-2005, 02:51 PM
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Compiling Comprehensive List of Maintenance
Folks, I'm in the process of gathering factory- and rennlist-recommended maintenance tasks into an easy to use and track format. Over the last few years as I've added two of these beasts to the fleet I've realized that even though I keep detailed records of maintenance and service on each I cannot remember which one is due for what maintenance and pawing through my organized records takes more time than I'd like. So, I'm working on a matrix-like format so that I'm able to see at-a-glance what service and maintenance is up-coming. Once I'm done I'll make what I have produced available to anyone who wants it.
I plan to do this for S4s or later. Anyone interested in doing the same for pre-S4s is welcome to take what I produce and modify it.
To that end, I remember seeing some very good posts on rennlist-recommended maintenance. I've been able to track a few down but I'm still searching for some. In particular
- WallyP (I think) once posted a nice list of pre-winter or once-per-year tasks. I recall that it included items like: cleaning grounds, the battery cables, etc.
Does anyone have a pointer to this post?
Does anyone have a pointer to other posts with good periodic tasks?
Does anyone have any input they'd like to share?
So far, I've compiled the list below. Shown are factory recommended intervals. I plan to include optional intervals based upon rennlist-recommendations (e.g. timing belt, etc.)
I plan to do this for S4s or later. Anyone interested in doing the same for pre-S4s is welcome to take what I produce and modify it.
To that end, I remember seeing some very good posts on rennlist-recommended maintenance. I've been able to track a few down but I'm still searching for some. In particular
- WallyP (I think) once posted a nice list of pre-winter or once-per-year tasks. I recall that it included items like: cleaning grounds, the battery cables, etc.
Does anyone have a pointer to this post?
Does anyone have a pointer to other posts with good periodic tasks?
Does anyone have any input they'd like to share?
So far, I've compiled the list below. Shown are factory recommended intervals. I plan to include optional intervals based upon rennlist-recommendations (e.g. timing belt, etc.)
Code:
Maintenance Item "Mileage "Time
Interval" Interval"
E-Clip check on headlight arms. 7,500 1/2 Year
Engine Oil and Filter Replacement 15,000 1 Year
Check Oil Pan Bolts 15,000 1 Year
Coolant Level Check 15,000 1 Year
Radiator FOD Check 15,000 1 Year
Crank Case Breather Hoses Check 15,000 1 Year
Fuel System Leak Check 15,000 1 Year
Battery Level Check 15,000 1 Year
Brake Fluid Level 15,000 1 Year
Power Steering Leak Check 15,000 1 Year
Throttle Cable Operation and Lub 15,000 1 Year
Windshield Washer System 15,000 1 Year
Lub. Door Hinges / Check Rods 15,000 1 Year
Clean and Lub. Weatherstrips 15,000 1 Year
Check tow hook plugs 15,000 1 Year
Engine and Transaxle Leak Check 15,000 1 Year
Exhaust Check (Leaks, Hangers,...) 15,000 1 Year
Transaxle Oil/Fluid Level 15,000 1 Year
Brake Disc and Pad Wear Check 15,000 1 Year
Front Wheel Bearing Check 15,000 1 Year
Steering System Check 15,000 1 Year
(boots, tie-rod ends, ...)
CV Joint Boots 15,000 1 Year
Brake & Clutch Check 15,000 1 Year
(Free-play, leaks, corrosion,...)
Parking Brake Free Travel Check 15,000 1 Year
Fault Code Check 15,000 1 Year
Flex Plate Check (Autos) Periodic 15,000 1 Year
Timing Belt Tension 30,000 2 Years
Tensioner Oil Level 30,000 2 Years
Spark Plugs 30,000 2 Years
Resonance Flap 30,000 2 Years
Intake and Air pump Filters 30,000 2 Years
Transaxle Oil Change (5-Speed) 30,000 2 Years
Coolant Flush 30,000 2 Years
ATF Fluid and strainer 30,000 2 Years
Brake Fluid Flush 30,000 2 Years
PSD Flush (MY 90+) 30,000 2 Years
Timing Belt Replacement 60,000 6 Years
Re-tension after Replacement 2,000 1/2 Year
Fuel Filter 60,000
Oxygen Sensor 60,000
Differential Oil Change (Auto) 60,000
Check, Clean/Replace Fuses/Relays 80,000 8 Years
Last edited by worf928; 04-30-2005 at 07:31 PM.
04-30-2005, 02:55 PM
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Failure Items
Below is the list of wear items/failure items I've compiled (so far) with my best-guess (if I have one) on the historic failure rate:
Code:
Item "Mileage "Time Interval" Interval" LH Brain (S4 and Later) 10 years Alternator ??? In-tank / Main fuel pump 10 years Radiator 12 Years Front Wheel Bearings Rear Wheel Bearings 10 years Clutch Slave Hose (5-Speed) 8 Years Shocks/Dampers 80,000 10 years Tie-Rods 120,000 12 Years Motor Mounts 100,000 8 years Intake - hoses, gaskets, coating 100,000 15 years Intake - knock sensors, flappy, idle stabilizer 80,000 10 years Window guides, roller felts 80,000 10 years MAS 80,000 10 years
Last edited by worf928; 04-30-2005 at 07:39 PM.
04-30-2005, 05:43 PM
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...oh,
Flex plate check - annual
Check cam chain tensioner pads - 60k miles ?
I think 6 years is too long for cambelt elapsed time replacement ? More like 4 years ?
Flex plate check - annual
Check cam chain tensioner pads - 60k miles ?
I think 6 years is too long for cambelt elapsed time replacement ? More like 4 years ?
04-30-2005, 05:47 PM
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Flex plate check for a/t cars?
Rod bearing check?
Pan gasket check or replacement? Check pan bolts?
Knock sensors, won't be found by bosch hammer on '87 and '88 cars?
Ride height check?
Check for vacuum leaks?
Wallet check for extra 928 funds?
Rod bearing check?
Pan gasket check or replacement? Check pan bolts?
Knock sensors, won't be found by bosch hammer on '87 and '88 cars?
Ride height check?
Check for vacuum leaks?
Wallet check for extra 928 funds?
04-30-2005, 06:59 PM
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Replace all fuses maybe every 5 years or so?
Simple easy task that I perform every 3-4 months: visually check to make sure the "e" clips are still in place on the headlight pivot arms, so the arm doesn't come off the joint, flex backwards, and perforate the radiator.
Clean and condition leather seats every 6-12 months.
Carry a fresh fire extinguisher and replace every couple years.
I didn't see an interval to check and re-charge the A/C system. That might be useful.
Simple easy task that I perform every 3-4 months: visually check to make sure the "e" clips are still in place on the headlight pivot arms, so the arm doesn't come off the joint, flex backwards, and perforate the radiator.
Clean and condition leather seats every 6-12 months.
Carry a fresh fire extinguisher and replace every couple years.
I didn't see an interval to check and re-charge the A/C system. That might be useful.
04-30-2005, 07:07 PM
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While I was waiting for more input I added the following to my list:
John, my 80k estimate on the MAS agrees with yours.
And I would love a copy of Wally's checks. I know I saved them and put them in a safe place.
Carl, John - Flex Plate! Of course! How could I forget that! (Easy - no autos in the fleet!)
Cam chain pads - John, I've looked at three sets of pads now, 75k, 105k, 120k, and the pads were less than 50% worn in all cases. Given that checking the pads involves 10+ hours of cover removal, I am inclined to list these as WYIT with other items, and/or 120k-miles and 15 years. (Thoughts?)
Also - WYIT - cleaning the oil check valves in the heads. And setting cam timing.
AH!! Sprockets! 120k-miles. Oil and Cam. Crank sprocket - check only.
Code:
Intake - hoses, gaskets, coating 100,000 15 years Intake - knock sensors, flappy, idle stabilizer 80,000 10 years Window guides, roller felts 80,000 10 years MAS 80,000 10 years
And I would love a copy of Wally's checks. I know I saved them and put them in a safe place.
Carl, John - Flex Plate! Of course! How could I forget that! (Easy - no autos in the fleet!)
Cam chain pads - John, I've looked at three sets of pads now, 75k, 105k, 120k, and the pads were less than 50% worn in all cases. Given that checking the pads involves 10+ hours of cover removal, I am inclined to list these as WYIT with other items, and/or 120k-miles and 15 years. (Thoughts?)
Also - WYIT - cleaning the oil check valves in the heads. And setting cam timing.
AH!! Sprockets! 120k-miles. Oil and Cam. Crank sprocket - check only.
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04-30-2005, 07:18 PM
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Good Stuff Folks!! Keep it coming!
Hmmm... my '89 was quite rejuvenated by a cleaning of the fuse and relay contacts. I think a 10 year interval for fuse cleaning/replacement would be fine. Other's thoughts?
Another DOH! How could I forget that one! GREAT!
Hmmm... I should add an interior/exterior care section. Perhaps.
True. Although I would think that checking the A/C happens a lot. It would be great if folks could opine on the relative lifetimes of the various A/C components. I have little data on those.
I'll be making edits to the first two lists as items accumulate.
Originally Posted by bigs
Replace all fuses maybe every 5 years or so?
...visually check to make sure the "e" clips are still in place on the headlight pivot arms,
Clean and condition leather seats every 6-12 months.
I didn't see an interval to check and re-charge the A/C system. That might be useful.
I'll be making edits to the first two lists as items accumulate.
04-30-2005, 07:30 PM
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OK. Added e-clip check, oil pan bolts. Flex plate. Below is the list of WYIT and/or after-service items:
Code:
Flex Plate (Autos) After Torque Tube R&R 0 ASAP
Check routing of vacuum lines After any related service
w/Timing Belt
Check Insulation on ABS Power Wire 100,000 10 years
Check Hall Sensor Connection
Check Oil, Cam, and Crank Sprockets 120,000 12 Years
w/Cam Cover Removal
Clean Oil Check Valves in Head 120,000 10 Years
Check Wear Cam Chain Tensioner Pads 150,000 15 Years
Set Cam Timing
w/Intake Removal
Clean Rotary Idle Actuator 80,000 10 Years
Check Operation of Throttle Switch 80,000 10 Years
Check Condition of LH Harness Grounds 120,000 10 Years
04-30-2005, 07:33 PM
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Originally Posted by John Speake
...I think 6 years is too long for cambelt elapsed time replacement ? More like 4 years ?
I will add optional intervals as they arrive.
Rennlist wisdom is 45k-miles and 4 years for the t-belt?
04-30-2005, 08:09 PM
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Originally Posted by Shane
Overhaul/service supercharger every 60,000-80,000 miles. 
04-30-2005, 09:26 PM
#14
Your suggestion is a great idea and if it can be computer based with a reminder system for when each item is due it could be an electronic version of a maintenance card system for the whole car.
As a base I would suggest you use the Porsche issued Maintenance Requirement Technical Bulleting for All models dated 13th October 1993 and it covers up to the 928 GTS.
I have compared this with the Service Information Technik for my 1990 S4 and this Service Information also covers the GT and they are very similar, so I use the 1993 to guide me in my maintenance/service requirements. By using the 1993 or later version (if any issued) it should have included the latest advice from Porsche.
Each member who elects to use the system you are developing could then vary the base system to suit special items related to their specific 928 model.
I would suggest that when you compile the system your vary the service/maintenance intervals as required by the information gathered from the user/owners/and tech experts who contribute to the 928 Forum (as you are now doing). This is the basis of many maintenance systems that I have helped to develop and used over many years with large and various machinery installations.
These systems have been initially developed from manufactures requirements, varied by the maintenance personal and service people using information gathered from on-job inspections, servicing and repair requirements and these system were initiallyed based on a card system.
The later developments were by 'predictive maintenance', as we have seen with one member of the Renlist Forum giving us his reports on the analysis of the engine lubricating oil with regards to metal traces, water content etc. however, I believe for our car the planned maintenace approach is best except when those of us that have the fault diagnostic system used by Porsche Centres of by the one that John from JDS Porsche has developed.
the system should also include the service intervals for the PSD system of 2.5 years the same as the brake system for a flush and inspection with brake fluid reservoir level check at yearly intervals or more often if required. I have noted that some owners seem to ignore the PSD system as it is "hidden".
I would also suggest that you also include the weekly checks of the engine lub oil, cooling water, brake fluid, so that total reliance is not make on the car's indicator fault system.
Also a visual check around and under the car once a month is another suggestion to cover any leaks especially the water pump, as well as the ATF level should be checked after the system has had a good run and is hot or every alternative month the ATF level is checked when cold, after engine running for a couple of minutes in "N".
I would also suggest that the timing belt is checked once a month via the vent holes after the air intake tubes are removed to check that it is in good condition and running correctly on the cam sprockets.
At each 12 month service I use the Porsche Specimen Measureing Chart for Wheels. Tyres and Alignment which is found in the WSM to record my ride height, my wear on my tyres (tread thickness as an average across the tread), the checking of my front wheel bearing for vertical and horizontal play as well as my brake pad thickness. The tread thickness checks give me a very good indication on how my wheel alignment is going and whether it requires to be adjusted. It also gives me a good feed back on my driving habits as the rear wheels wear much quicker than the front especially if too much power is laid down too often.
I have assembled a file of all my service jobs from extracts from WSM, 928 forums, Porsche Technical Bulletins, Wally's Annual Electrical Maintenance, oil specification sheets and Material Safety Data Sheets, Porsche Service Information Technik for my year model car, Technical Specifications Booket, Owners Manual etc., so that I have compiled a very good data base of 'what should be done and when' and "how to do it".
Oh! Another suggestion is to annually carry out a "Current Constant Draw" test as per Technical Bulleting covering the S4 dated December 2, 1988 as well as plot out a system to clean up the earth points on the care on a maintenance schedule cycle.
Hope the above helps and I'm very intereted in your schedule's development.
Tails 1990 928 S4 Auto
As a base I would suggest you use the Porsche issued Maintenance Requirement Technical Bulleting for All models dated 13th October 1993 and it covers up to the 928 GTS.
I have compared this with the Service Information Technik for my 1990 S4 and this Service Information also covers the GT and they are very similar, so I use the 1993 to guide me in my maintenance/service requirements. By using the 1993 or later version (if any issued) it should have included the latest advice from Porsche.
Each member who elects to use the system you are developing could then vary the base system to suit special items related to their specific 928 model.
I would suggest that when you compile the system your vary the service/maintenance intervals as required by the information gathered from the user/owners/and tech experts who contribute to the 928 Forum (as you are now doing). This is the basis of many maintenance systems that I have helped to develop and used over many years with large and various machinery installations.
These systems have been initially developed from manufactures requirements, varied by the maintenance personal and service people using information gathered from on-job inspections, servicing and repair requirements and these system were initiallyed based on a card system.
The later developments were by 'predictive maintenance', as we have seen with one member of the Renlist Forum giving us his reports on the analysis of the engine lubricating oil with regards to metal traces, water content etc. however, I believe for our car the planned maintenace approach is best except when those of us that have the fault diagnostic system used by Porsche Centres of by the one that John from JDS Porsche has developed.
the system should also include the service intervals for the PSD system of 2.5 years the same as the brake system for a flush and inspection with brake fluid reservoir level check at yearly intervals or more often if required. I have noted that some owners seem to ignore the PSD system as it is "hidden".
I would also suggest that you also include the weekly checks of the engine lub oil, cooling water, brake fluid, so that total reliance is not make on the car's indicator fault system.
Also a visual check around and under the car once a month is another suggestion to cover any leaks especially the water pump, as well as the ATF level should be checked after the system has had a good run and is hot or every alternative month the ATF level is checked when cold, after engine running for a couple of minutes in "N".
I would also suggest that the timing belt is checked once a month via the vent holes after the air intake tubes are removed to check that it is in good condition and running correctly on the cam sprockets.
At each 12 month service I use the Porsche Specimen Measureing Chart for Wheels. Tyres and Alignment which is found in the WSM to record my ride height, my wear on my tyres (tread thickness as an average across the tread), the checking of my front wheel bearing for vertical and horizontal play as well as my brake pad thickness. The tread thickness checks give me a very good indication on how my wheel alignment is going and whether it requires to be adjusted. It also gives me a good feed back on my driving habits as the rear wheels wear much quicker than the front especially if too much power is laid down too often.
I have assembled a file of all my service jobs from extracts from WSM, 928 forums, Porsche Technical Bulletins, Wally's Annual Electrical Maintenance, oil specification sheets and Material Safety Data Sheets, Porsche Service Information Technik for my year model car, Technical Specifications Booket, Owners Manual etc., so that I have compiled a very good data base of 'what should be done and when' and "how to do it".
Oh! Another suggestion is to annually carry out a "Current Constant Draw" test as per Technical Bulleting covering the S4 dated December 2, 1988 as well as plot out a system to clean up the earth points on the care on a maintenance schedule cycle.
Hope the above helps and I'm very intereted in your schedule's development.
Tails 1990 928 S4 Auto
05-01-2005, 07:03 AM
#15
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928 & RC51. The Hammer will check knock sensors on an '88. The "problem" is that a 12way lead was never made by Porsche for the 12 way connector used on this MY. (I can supply them)
Also, a MY 87 928 is wired for diagnostics, it just requires an EPROM swap in the LH and EZK ECUs.
(I can supply these too)
Dave,
I think you need (maybe) to split this into seperate sections ?
During cambelt change - replace bushes in tensioner arm ? Replace boot on tensioner ?
For manual car (any age) I would recommend replacement of the clutch pedal plastic ball joint with a metal one - I hear of many failures of these. I have sourced a metal part.
Also, a MY 87 928 is wired for diagnostics, it just requires an EPROM swap in the LH and EZK ECUs.
(I can supply these too)
Dave,
I think you need (maybe) to split this into seperate sections ?
During cambelt change - replace bushes in tensioner arm ? Replace boot on tensioner ?
For manual car (any age) I would recommend replacement of the clutch pedal plastic ball joint with a metal one - I hear of many failures of these. I have sourced a metal part.