Stuart Waite

Hi John
Thanks for the email. I have just sent you the funds via Paypal for the J.Kempf tool. You know I said it was a small world well, I thought your name was familiar to me and low and behold whilst I was filing your email I came across another email from you from May 2003........you were kind enough to supply me with my workshop manual after Wally Plumley put us in touch!
Regards
Stuart

Stuart Waite

Hi MrMerlin
Further invesitagtion shows that there have been two part numbers for the tension arm bushes. My PET schematic shows 928.105.613.03 but the OPC are showing replacement 928.105.613.04 I wonder which colour is which?

Mrmerlin

The tan ones i got were from Roger give him a call Roger@928srus.com

Landseer

The different colored bushes go on different tensioners.

Stuart Waite

Hi Chris
Can you be more specific please

John Speake

Thanks Stuart, I will post the tool to you tommorrow for Friday delivery.

John

Mrmerlin

NOT TRUE the dark gray ones are from a different vendor/manufacturer, the tan ones are for the same application they just fit tighter

Stuart Waite

Hi John
Tool arrived in post this morning thanks :-)
Bits from OPC still not arrived though!
Thanks again
Stuart

oz928s4

Stuart
where do the bushes reside that you are wanting...not sure.
Give me a description...as I said I have all the parts there.
The guide plate is 23.75 ozzy dollars to send in a 4-7 day service..that said it takes 10-12 days.
paypal is the go...peter@becnt.com.au
I will send it off once you confirm the bush location in case they are the ones you want.

regs
Peter

Sorry for slow responses as I have been fitting a supercharger to my s4 and it has consumed me.
got it running today but it got hot as the fans refused to kik in and it went into limp mode I think....
Went from running to not running and I had to walk away as it started getting hot.

Mrmerlin

just to be accurate, the tan bushings I am talking about are for the bushings that ride on the tensioner pivot arm.
I had to use a piece of fine grit sand paper to polish the bushes B4 they would fit into the arm and dipping them in hot water made installing them into the arm easier I used a vice to press them in, and also polished the pivot arm for a tight fit.
Since i have installed them no more warnings from the belt tensioner warning circuit

Bill Ball

I chamfer the leading edge of the bushings and use either a C-clamp or vice to slowly press them in. Getting them started straight is the key.

Stuart Waite

Hi Peter
Sorry for the delay getting back to you - I hope it's given enough time for your's to cool off!
I've rebuilt it all last weekend with new bushes from Porsche so the only bit I need now is the lower idler carrier. I'll send you the funds via Paypal when I get into the office in the morning.
Hope your big fans on the outside perform as well as the little one you have fitted inside!
Regards
Stuart

Stuart Waite

Hi guys
Well I've rebuilt all the timing gear with new bearings, rollers, bushes (dark grey ones) with the exception on the lower idler assembly and it purrrrrrs. It is beautifully smooth and quiet and the tapping noise has completely disappeared. It would therefore appear that a small amount of play in the lower idler can indeed make the 928 do a passable impersonation of a diesel tractor!
I have new lower idle rollers assembled ready & waiting and as soon as the repacement carrier arrives from Australia (thanks Oz928s4) I will slip these into place. It seems that this can be done just by removing the front pullies and dual mass damper without having to strip anything else.
I tensioned the timing belt by hand as before but this time used the J.Kemph tool to confirm the tension - the pointer showed just on the tight side limit of the correct value. Does anybody know how accurate these tools are? If the factory tool should indicate 5.2 how does this relate to the notch on the J.Kemph?
May I take this opportunity to thank all the members for their invaluable help and comments during the diagnosis and rectification of this problem
Regards
Stuart Waite

the flyin' scotsman

Glad it worked out but be this a lesson to all.

IMHO the antiquated OEM tensioner system needs much attention that cannot be skipped. If your decision is to go forward with the OEM set up do all the maintenance not part of.

As stated the Porkensioner eliminates 95% of the maintenance............my personal choice.

oz928s4

Stuart
paypal rec/vd will shoot it out tomorrow morning for you.