F18Rep

Morning sportfans... here are some pics of my 928 project. I got this 83 5-speed about 3 weeks ago and have been digging in to see what I need to do to make this a daily driver. It has 135k and a variety of tired interior and cosmetic issues but overall it is unmolested. I trailered it home but could have driven it. It has a broken exhaust manifold stud and two welds broken on the Y pipe that made it a little noisy.
I just got the heads off and am still hopeful that I won't need a lot of work on the rotating assembly. So far, I plan to do the basics (wp, tb, fuel lines, cam gears, rod bearings and fix some oil leaks). Not sure on the heads yet. I have the interior gutted and will re-upholster the seats and swap-in some new carpet. Comments welcome... [928 Grasshoppah]

PS... I had to evict a mouse from his winter hide-away in the engine valley. ;]

S4ordie

Great color on the car! Lots of projects to be sure. Will be fun to watch your progress. Is your intent to basically overhaul the entire car. I said overhaul not restore. That cam gear looks really worn. As a long time Rlister you've already got a good idea of what is required for this project.

Good luck!

Landseer

Nice. Way to attack.

Rehab is an interesting word.

F18Rep

Update: not much progress but getting a first look at the cylinders. Just a quick look after vacuuming, but this is the only spot that I see as a problem. Does anyone think this is a show stopper? Also, all four cogs are spent. I guess I've heard this is a "928 thing" but still it seems something is wrong that this can happen. Never seen anything like this on the step-child 944 engines. Replacing those will be a hit, sure hope theres a good deal on these somewhere? Head gaskets were Porsche brand, sorta makes me wonder if this puppy has ever been opened up....Bruce (aka Pop)

Landseer

Typical 928.

F18Rep

September update pics...
Note the stud - almost unreachable in situ

Before super-clean (note the recycled bedliner for a grease catcher)

After (not show quality, but better)


Interior gut is underway

Some general issues with clutch (found a broken spring in the slave too)

with country-boy tow vehicle

Bruce

namasgt

Are you going to change those fuel lines on pic #4 ?
Its easier with the engine out. If you do, use 30R9 gates brand, Roger sells them.

86'928S MeteorGrey

Belt gears aren't too much depending on where you get em. The one thing I ever got good from Mason Fine was a pair of perfect cam gears for $50. I had a steel oil pump gear and good crank gear standing by. That damage is usually from someone over tensioning the belt. The mounting shoulder bolt can also be bent with the same action. One word. Porkensioner.

Nice grab. Looks like this lady is going to give you good therapy. I often go in for wrench therapy with my 928 for a 4 hour session, and she will give me an 8 hour session free of charge!

Mrmerlin

lots of other things that can be done.


the crank drive gear may be OK put a straight edge across the teeth see how much wear it has./
The oil pump gear is aluminum the new part is steel ..
SO remove the 1mm washer behind the aluminum gear when you fit the steel gear.
Replace the oil pump radial seal and O ring as well as the 3 bolt O rings, I use Dow Corning 111 for the O rings ,
use STP in the oil pump gears when you reassemble,
Note the oil pump outer gear has one outer edge thats beveled this must face to the front of the car,
the dots on the gears should both face to the engine.
Remove the washer fill tube and take out the metal collar do the same for the washer tank. then wash out the tank.
Inspect the coolant bottle now is easy easy time to replace it if you find any cracks.
swap out the fuel lines
Get new motor mounts use the Volvo mounts.

Wash out the well where the drain is for the firewall, make sure your blower box isnt leaking water onto the CE panel,
inspect after the wash to verify a dry floor

F18Rep

Good comments, thanks.
Yes I'm doing the fuel lines - not exactly sure how yet though - pretty sure I have most of what I need from my 944 & cummins days.

Motor mounts are on the list and still need commit on those. I don't expect to go back to Porsche but I'm still confused on what the consensus is beyond that.

The coolant bottle is a good thought too. I know I have to get it out to do the hoses - hoping to not have to replace it, this is a budget project afterall.

I haven't really studied the tensioner situation, I do have a replacement gear for the oil pump and crank. I may experiment with powder coating or something with the cam gears though [ducking]...

What I would really like is for someone to point to a hose PN to replace the rubber section of the PS return line (hint - not Porsche). ;]

86'928S MeteorGrey

Don't even think about PC the cam gears. The hard anodize will wear forever if the belt is tensioned properly. As soon as the hard anodize wears off, the aluminum acts like butta' to the belt. I believe the cam gears go for somewhere around $50-$70 bucks each at 928 intl...used... About $100 each new. Don't mess with the cam gears, it's not worth it. There is material worn away which means it will never be right.

Do a search about motor mounts, or even better, just give Roger a call at 928sRus... He will clear up any confusion about the MM.... And give you the best price too....

Replace the TB with a Gates racing belt. If not the new reinforced Gates, use Porsche only.

If you don't want to worry about belt tension on your cam gears in the future, the Porkensioner is the ONLY way to go. You also won't have to tear it all apart to re-tension after 1K miles...

pcar928fan

When I read the title of this thread I thought it was for those of us who have to many 928's already and can't stop buying them! LOL!

Good luck on your project! You are a saint for saving another one!

antsmands

That's gonna be a nice 83 when you are done with it. Of course I am partial to the 83 5spd!

Good Job!

jeff spahn

I like the 4x4 look with the engine out. Hey now there would be a great project. Find a way to put an Audi A8 driveline in a 928. . . . hmmmmm

pcar928fan

Jeff, you need something like this I guess!