928autobahndreamer

One more thing, just in case anyone plans on "outgassing" their intake in the kitchen oven, be warned. I did this and the amount of toxic smoke that poured out of the oven was a little scary. I ended up doing multiple heat cycles by heating up until it started to smoke heavily and then removed and let it continue to smoke outside. Then I would bring it back in and do it all over again.

I can't remember who I asked, but I did make a post here asking if i was going to release a lot of toxic smoke and was told "No".

So, I heated it until it no longer smoked and it is now ready for paint.

Oh, I also ran it through about 5 cycles in the dishwasher on the pots and pans cycle. Mostly before, but also once after the outgassing.

Fortunately my wife was understanding about using the kitchen as my parts cleaning station.

dcmelik

Good job. Looks like this means I will have a similar little helper in about 8-10 years, as my son is 25 weeks old this week, although yours looks like he's especially adept at wrenching.

928autobahndreamer

You won't have to wait that long. My little guy is 4.

Bill Ball

I've never heard of any wife before that would agree to this.

928autobahndreamer

Next question.

I am now at the reassembly portion of this adventure. Looking at the gasket between the throttle body and the intake it appears to be two sided. One side has a blue rubberized bead running most of the way around it and the other side is smooth and is a light orange color.

Does it matter which side is up?

My old gasket appeared to be the same on both sides although it is hard to tell due to all of the paint that came off of the intake side.

BTW, Bill. The parts cleaning in the kitchen was only after countless hours of cleaning first in the garage and driveway with scrub brushes, multiple rolls of paper towels and buckets of water. Once no more visible grime was present, then the parts are allowed inside. However, she has still been very patient with my little project.

928autobahndreamer

I'll try to take some pictures of the gaskets in question tonight, as well as some pictures of my new purdy intake paint job.

928autobahndreamer

Alright, here is a picture of the TB gaskets. Any difference which side should face towards the intake and which should face the throttle body?



Also, as promised, the final result of way too many hours of prep work .

the flyin' scotsman

When I did my intake R&R last year I don't recall the gaskets being a dilema (certainly were not same as the pics) but given your pics I'd put the glue side toward the piece thats most uneven............the intake.

928autobahndreamer

Sounds like a good plan. Thanks.

I was a little concerned that the glue bead does not seem to go the entire circumference of the gasket. Seems like this would leave an avenue for a leak.

928autobahndreamer

Getting closer.

I actually feel like I may make it. All that is left is the fuel rails and injectors and the little things after that. I just hope that after all of this work it runs better and not worse.

I have tried to be really carefull. But, even with bagging everything and following Dwayne's writeup obsessively, and taking my own pictures, I ended up with a leftover bracket. For the life of me I can't figure out were this is supposed to go. It is the L shaped bracket I'm holding in my hand in the photo. It was bagged with my hex head bolts for the water bridge. This is not the bracket for the fuel line. That is more straight and is attached. Any ideas?

Anyway, I will also attach some pictures of the progress so far as well. I think it looks pretty good for a homemade job.

928autobahndreamer

Well, the saga continues. Got everything buttoned back up. But before I put on the airbox, I fired her up to see how things were.

Well, after the fuel system pressurized, she turned over and settled into the correct idle. Great, but there has got to be a minor air leak somewhere, because there is a high pitched whistle coming from under the intake. I think it is coming from the hose that comes off of the MAF boot as I am not really happy at how this hose is situated and it is ever so slightly torquing the plastic connector to the MAF boot. I am going to have to go back and make sure this hose is routed correctly and make sure it is oriented right.

Arrrrrggggg. So, close. Man I just want to drive again. To make things worse, my wife and I just had the "need to spend more time together talk". So, it is going to be hard to find garage time.

The joys and frustrations of 928 ownership. A big Thanks to all who have listened to my blathering and especially to those who have posted help and/or encouragement. Also, a special thanks goes out to Dwayne, without whom I would still be sitting in the garage with the car in pieces scratching my head.

blown 87

I am not sure I have ever even heard of anyone that liked cleaning parts before I read your post.

The other Greg

the flyin' scotsman

The bracket fits on the drivers side water bridge under the bolt closest to the fuel rail.

Check the hoses on both sides of the MAF boot...........hopefully its reachable from up top

928autobahndreamer

Thanks Malcolm. I figured it had to be one of those bolts on the water bridge since the bracket was in the bag with those bolts. I just couldn't figure what it was supposed to secure. So, I'll get that reattached right away.

Otherwise, I didn't get a chance to look at my car last night. But, I think it has got to be that hose on the drivers side connecting to the MAF boot. For some reason it is not laying like it should. If I can get those little issues straightened out I should be good to go.

As I said, the idle was correct and steady except for that very high pitched whistle. There were no fuel or oil leaks. So, hopefully one more evening of work and I can take her for a drive.

928autobahndreamer

The high pitched whistle was from the breather hose to the oil filler neck on the passenger side. I guess I didn't get it tightned properly and it came loose when positioning the intake. I noticed that it was mostly off when looking around under there. I didn't see any way to reattach, so off the intake came again and hoses are now all tightly attached. I have gotten as far as tightening down the intake so far. But I have to be at work in 5 hours and need to get a little sleep.

Next problem relates to the water bridge bolt near the firewall on the drivers side. I was having a hard time getting it to thread, and finally got it started. So, I start to ratchet it in. But, I notice that there is a little more resistance than there should be. Unfortunately, I think I cross threaded the bolt and now I can't get it to go in except for threading easily for the first few turns and then increasing in resistance significantly. I haven't had this happen before. What can I do to fix this? I really want to get this finished for the weekend. My brother is coming in to town and I wanted to take him for a great drive in the 928.

Please help with any ideas.