Congrats! Quite a journey you embarked on there. Must feel pretty awesome to hear it run.

 

Okay, it runs. The clutch is like butter.....

But I've got a fuel leak that I just can get fixed.

The banjo fitting on the fuel distributor feeding #5 is killing me. The one on the far right.


Of course I've run out of crush washers, so hopefully Porsche has some in the parts department Monday morning.

But I tried a punt as per another recent thread. Resurface the banjo fittings and see if that works

There were some deep groves.


I used a sanding block with 400 paper and WD40, then polished up with 1000 paper and WD40.


I put it back together, and even torqued it to the right spec, and guess what. I'll still be off to Porsche monday morning looking for crush washers. I think the washers are the problem now.

I'll see if they have a banjo bolt and banjo fitting while I'm there. The surface of the fuel distributor looks fine. Wasn't leaking before.

 

Dan,

I am only seeing one crush washer. Are you putting one on top and one on the bottom of each banjo fitting?

Dennis

 

Yes! That one just happened to make it into the picture.

I see Pelican sells a big assortment of copper crush ring for a couple hundred. Something my garage should have.

 

Dan,

I like to take a flat 1" fine tooth file gently over each mating surface. This will help true the surfaces and show any divots that wouldn't show up with sanding.

Dennis

 

Dennis, that file trick trued up the surface nicely. Polished it with 400 grit.

This morning, I drop by Porsche parts for some sealing rings. He says he needs to order them, you know its a 928 part. I kept my cool and tell him its a common 911 part. And he pulls out the magic box full of copper sealing rings and gives me 6 - free of charge.

Figure I'll try for a banjo bolt and fitting while I'm there. Bolt is $25, so I passed. Figure it's not the problem anyway.

The Banjo fitting is part of either the left or right bank fuel line assembly, and yep it's expensive - $500. So guess what, I passed.

I get home and try again with the new sealing rings. No luck, I still have a leak.

I can't imagine I'm not getting a good seal. So now I think its the banjo fitting itself.

I think I have a bad seal where the threaded tube is pressed into the banjo housing. I can see a crack or a gap on one side.

So, I'll see if I can locate a used one in decent condition.

Wish me luck. I'd really like to be driving this beast around right now.

 

Might try cleaning and using teflon tape on the threads of the banjo fitting. It appears they have had some type of sealer put on them earlier.

Dennis

 

I used to be into dirt bikes back in the 80's, they used copper head gaskets. Those head gaskets looked like a larger version of a crush ring. We used to reuse them all the time by following these steps. I can't see the crush ring being any different, and might be a quick fix if in a bind:

http://www.powroll.com/PDF/2007%20-%...PER-GASKET.pdf

 

this is where I think I've got a leak, where the threaded pipe is pressed into the banjo housing.

 

Good catch on the fitting. That's one area you wouldn't normally check.

Dennis

 

I cleaned the fitting up, and

epoxied the banjo fitting. It seems to have stopped the leak. So it looks like I've found my problem. Have a used banjo fitting in transit from 928Intl.

I do have a bit of seepage coming out of the pressure regulator at the back of the fuel distributor. (Of course I don't have the proper size ring for that.)

Oh yeah, I took the car out for a spin around the neighborhood. And then I took the kids for a ride.

 

Dan,

Since there is no banjo fitting on the valve, that has to be the ring. Your local auto parts store may have an aluminum seal that would fit.

Dennis

 

I do want to close out this thread with a picture of the NYS inspection sticker on the window. Street legal. That's a good way, right?

Over this weekend, I went to 3 local shops that do NYS inspections. In NY, you have the full blown dyno road test emissions inspection, and for old buggers (25 years or older I do believe), the usual inspections (lights, brakes, etc) and no emissions test.

All the data is keyed into a machine for data verification and collection by Big Brother. Here's the strange part. There are 2 machines, one for old and one for new cars.

Well the machines for the older cars at all three shops I went to are broken. (I watched one not work, and was told by the mechanics that the other 2 were broken.)

What a royal pain in the ***.

I'll try again next weekend at new shops with a little prescreening during the week.

And what's "wrong" with my old 928 now?
Suction side of the PS pump has a leak that just doesn't want to fix
Front ride height is about 1" too high after the Bilstiens/adjustable plates installed. Any one else? Is cutting a coil off the springs an option?

That's it!

 

Glad to see the OB back on the road even if it isn't inspected. Concerning the ride height, you may want to give it more time and miles to settle.

Dennis

 

I thought the best way to finish this thread would be to have her inspected and back in service. Well, looks like after a year and a half, I'm there.

I'm gotten great advice from many of you and the words of encouragement kept me going. So big thanks to all of you! While I might have gotten it done without you, it wouldn't have been as much fun and I'm sure not as successful!

As with most things in life, you're never really finished, just at an ending moving on to a new beginning (recent HR course on that one ha ha).

Well, the story is a few weeks back, I drove my old bugger to the shop to get the inspection sticker. I forgot my registration, so I had to drive home to get it. When I pulled out of the parking lot, I see she's dumped power steering fluid all over the place.

So off to ebay to get a rebuildable pump (the early 78's came with a unique ps pump that cannot be sealed). The pump arrived, I installed it without resealing it, and it works fine.

The auto shop gave me my inspection sticker (even with the coolant drip from the crack in the end tank).

So, here it is - LEGAL.


I'll be buying a new aluminum radiator soon. And the damn front end will not settle properly with the bilstiens and adjustment gear. So, I be pulling those and cutting the coil springs. And I'll have to finish the aircon asap. As well as decide when it's time to fix the peeling paint on the bumpers from the paint job 7 years ago. But, that's another thread....