worf928

Folks, I'm in the process of gathering up information and topics for a massive update for the third revision of my '87-'95 intake R&R tech procedure (available at The OC Site and at 928 International.)

In the 10 years since I wrote the first revision all our cars have aged to the point where there's tons of stuff to do when the intake comes off and I'd like to add that to the guide. And I've done it so many times now that I've learned some new tricks that can go into the guide too.

Below are the topics I'm going to add to the guide, if you have additional stuff you'd like to see in Revision 3 post your ideas here. (Or if you think I shouldn't waste my time with a revision, let me know that too.)

Also, if you think the second revision had some problems, or if you have some of your own tricks not in the guide or not listed below, feel free to post your thoughts.

I'll add attributions to the third revision for anything non-trival or anything super-nifty (so long as the attributions don't swamp the text of the procedure.) And of course those folks will get a cut of the massive residuals from the guide.


Beyond Intake Removal:
- R&R of flappy vacuum actuator
- ISV R&R, testing, and mount replacement
- WOT/Idle switch R&R, and testing

WYAIT tasks:
- LH harness ground cleaning
- Fuel line checks
- speed sensor checks
- MAS rebuild
- Knock Sensors
- primary vacuum system (5-way, dampeners, regulator, elbows, tank vent, air pump)
- secondary (accessory) vacuum system (flappy and check valve only)

Tips/Tricks:
- p-side breather hose routing
- N+1 ways to remove injectors and/or rails

Powder-Coating Pre-work
- flappy disassembly and correct re-assembly

Slippery Slope:
- filler neck (plastic and metal)
- coolant bridge (and powder-coating pre- and post-work)

Model Year Differences
- GTS breather hoses
- early '87 intake

Pre-start tests:
- fuel system integrity

Post-start troubleshooting:
- bad/high idle
- no start
- coolant leaks

Randy V

Very timely, Dave!

worf928

Randy? You about to do your intake

Rob Edwards

I haven't looked at version 2 recently, so some of this might be there already?

You might consider adding (if not already covered by your outline above):

Model year specific changes in fuel lines?
Flappy bearing part #'s and removal?
A table of all torque values?
Vacuum line Oetiker clamp removal and re-installation tools
injector harness connector repair (links to eagleday, etc)

WYAITs:
Crank position sensor?
Coolant tank?
Washer reservoir neck?
heater hoses in addition to heater valve?

RyanPerrella

you know what you need

a tool that removes flappy bearings in 1 minute. That would be awesome

I am not familiar with your guide, but i am glad your taking the time to produce one and update it.

Keep up the good work

the flyin' scotsman

Dave..........I believe you've covered most items for the project; perhaps some discussion re. all the hoses and gaskets, your findings and the necessity for complete replacement.

Let me know if you need any pics; I'm waiting for my 'gasket kit' to come and the weather to warm before re-assembly.

ROG100

My Wish is that you come and do a couple of mine for me 8>)

worf928

No problem. We can discuss a discounted rate for volume work.

worf928

Yes, it would. That would qualify as a non-trivial and super-nifty thing to add to the guide.

So... how would one make such a tool with parts from the local Home Depot and 7/11?

Speaking of other non-trivial and super-nifty thing's, I'd like to figure out a reversible non-destructive way to dismantle the ISV. Legend has it that it can be done. I will be digging out an old one I have to see if I can figure it out.

worf928

Malcolm, I've got a fair number of pictures if the mechanical bits. What I don't have are any pictures of replacing the 2, 3,& 5 pin harness plugs.

worf928

AFAIK there's only one break (post '86): mid-to-late '87 where the return line set-up changed. I was planning to at least mention it. I don't (yet) have a good picture of the '87 return line set-up.

Hey - Roger - I was thinking about the above last night. Have you an option for your line kit for the '87s with the 'console' connection from the regulator to the cooler?

I'm not sure what you mean. There are no clamps on the vacuum lines AFAIK. The clamps on the breather hoses are the screw-type, so that seems straight-forward. What clamp / line are you referring to specifically?

StratfordShark

Dave,

To go with all the new hoses I'll probably fit new hose clamps, unless the old ones clean up really well.

This is a pretty trivial suggestion but maybe a list of all the sizes required, so that people can pick up some aftermarket ones rather than buying Porsche ones using PET?

The clamps I took off the RHS breather pipes did have actual sizes engraved on the clamp which saves measuring.

RyanPerrella

As for an ISV, I bought a brand new Bosch one for $120 i think at autozone

They are a STEAL!

worf928

Monday bump.

heinrich

Dave Dwayne's guide on re-sealing the oil filler without removing the intake brought a thought ... how about a "without removing the intake" guide also ... ie can it be done ... flappy; throttle body, breather hoses; water bridge ... and how about an "improve/redesign your breather system" section .... here I'm thinking of putty hoses that need to be replaced ... but also perhaps re-routing and even cam cover outlet alteration?