cpayne

Well I have started earlier than I wanted to on the R/R of The Black Pearl.
With the wifes blessing and some great friends I have met on rennlist, the following can be crossed off. But before that some thank you's are n order.

Jim (Jadz929) for helping start a project list and walking me through the TB/WP inspection and tidbits of knowledge to get me started. Also the Porken 32 vr timing tool.

Roger at 928SRus for all the parts and help. This is only the beginning of parts purchase, so don't retire until I get through buying what I need Roger.

Lastly and I can't thank this guy enough. Chris (Landseer). What a great guy. Knowledgeable inventive , Chris worked his A%# off with me for two full weekends to get the items below complete. Just got back from his place at 12:20 AM EDT . We used his place, his tools, cleaners etc. Ate his food (His wife makes great sandwiches.) Can't thank you enough man. Awesome!


Completed

Key heads ,lights and batteries replaced. (All me)
Visor clips updated . (All me)
Rear hatch motor and release switches. (Thanks Alan great write up and wire tie solution!)
Idling and sticking throttle. (Thanks Jim)
MAF Tuned Injection Labs (Chris let me borrow one until mine gets repaired)
TB WP replacement . Gates belt and Laso pump. new wp bolts
Tensioner and pulley R/R
CAM gears , oil pump gear and crank gear replaced (Chris can post pictures as he had a camera man take some photos.)
Power steering pump rebuild, lines and reservoir replacement
Oil pump refresh.
Front main seal replace.
Thermostat and inner and outer seal replacement.
Cleaned everything.
New alternator belt and added AC belt.

November 29 2010
Alarm system removed. (Jim)
Wiring put back in order.(Jim)
CE panel R/R (Chris)
Fuel Lines (Kevin, Chris, Jim, Me)
Heater Valve and hose (Me, Kevin)
Crank Sensor (Jim)
Grounds cleaned (Me)
ISV Cleaning (Jim)

Here are pictures of the parts management work space.



Here is the front of the engine after some serious first round cleaning

Jadz928

Wow Charles! You just made that car your bitch.

Landseer

Car needed somebody to take charge, that's for sure.
Bit us a couple times.
Best was late last night, 90 minutes from startup.
Went to screw in the thermostat hose nozzle --- discovered that the lower bolt had been stripped long ago.
Dodged the bullet --- had some M6 X 1.0 helicoils --- manipulated access and got one segment in.


The belt, gears and tensioner on this 87 Seattle car definitely needed immediated attention.

The rest was WYIT.
Good choices on what to address.

Front engine harness is sketchy. Needs fuel lines soon!!!


Charles' crank gear is on the left.
My wife's 86 (@73K doc miles) is on the right. Both are sharp on edges
New $125 piece in center.

They are steel and the belt definitely wears them. Lots of flying grit under an old TB cover to create sandpaper action.

When replacing everything else the belt touches, its worth replacing this too.
Otherwise, the corrected tracking will locate the inner edge of the new belt overtop the sharp inner edge of the crank gear.
Not optimal.

Stromius

Great to see!

Ninespub

cpayne: Great job on the visor clips! I'm at about the same level of personal capabilities. Its the little victories......lol!

cpayne

Thanks Jim. Your list and advise were right on. Thanks for the tools to set the timing. We dialed it in really well. car is running like butta .

cpayne

Can't drive if you can't see. Good first option they are a good investment.

Landseer

I'll update Charles' thread this time.

The car runs great, new Gates timing belt is fine.


We completed the timing belt job a few weeks ago.
70 miles into the break-in, a tb warning light.
Pulled the covers, did a quick tension check --- saw top-of-window.
Tracking looked pretty good. Little bit of belt residue in cover.

Well, I didn't set the machine to TDC before making that measurement.

Fast forward to this aft. Set car to TDC.
We saw bottom-of-window on Kempf.
Rotated / measured / rotated /measured (at TDC) --- same result.

We reset tension, rotated and rechecked a few times.
Added nearly a turn on the screw in-total.

Belt tracks. Car runs great. This is a beautiful S4, no rubs, 5 spd, sport seats. Congrats, Charles, for the car and the patient approach.

cpayne

Thanks Chris. the credit on this goes to you. I would probably still be fiddling with getting the TB covers off. Your mentor-ship is priceless as is Jims. Just hope I can help you guys as much as you have helped me. Haven't figured out how yet. Anyway thanks again.

cpayne

Latest updates to The Black Pearl.

I want to thank Jim (Jadz928), Chris (LandSeer), Kevin (KevBolecy) for their time and patience in regards to helping me check some more things off my project list.
Jim was great in offering the space, tools and overall skills both electrical and mechanical.
Kevin was invaluable for his mechanical skills, ability to keep us laughing and willingness to jump in and teach me a few things along the way.
Chris for coming buy and using his enthusiasm and expertise and special tricks for figuring out how do do things faster and without hurting myself.

The original project plan was to pull my 3rd party Alarm and put WD 40, Brakleen, in the iSV to help my rough running in the morning and high Idle. KEvin was coming Down from Northern VA and we were going to take once the work was done. I arrived at 9:30 at Jims. Took a few photos of the Perl and The Black Pearl. (See Pics)

Jim asked what I was doing while he was pulling the Alarm. I said I was putting in a heater valve to fix my always on hot air issue and maybe Grounds in the Rear left and right points . Maybe the fuel lines. I had forgotten to bring the fuel lines, but Jim let me take Perl to get them. Kevin had arrived as I was leaving.
When I got back the hood was off my car, Chris had arrived and before I could get the fuel lines unpacked Chris had pulled the CE panel and was dremeling fuses and replacing relays like he was getting paid by part. Jim was pulling wires out like a Tasmanian Devil. (See Attachments) Kevin and I worked on the fuel lines . ( I know Electrical work , and fuel line work at the same time). We joked about what the headlines would say.

After all was said and done at 9 PM we were ready to pressurize the fuel lines and check for leaks. When we realized the keys were missing. 30minutes of searching and tearing the car apart, we were ready to go get the second set at my house, when we started to get testy with each other and point the finger. I looked up and saw the keys in the trunk lock. I'm not going to say how the got there, but I take the blame for it. Pressure showed some leaks tighten those up and did the ISV cleaning.
The car ran and idled fine, but made a loud noise near the oil pump. Sounded like a water pump impaler or oil pump Both replaced with Laso and oil pump and gear replaced during TB change.

Here is what was completed:
Alarm system removed. (Jim)
Wiring put back in order.(Jim)
CE panel R/R (Chris)
Fuel Lines (Kevin, Chris, Jim, Me)
Heater Valve and hose (Me, Kevin)
Crank Sensor (Jim)
Grounds cleaned (Me)
ISV Cleaning (Jim)

Jadz928

Charles,
It was a good time!
I really like getting rid of foreign wires... like Virginia creeper in Kentucky blue. It was a serious PO hack-job.
'Round 6 o'clock Charles looked at me and said "we won't finish today", and I replied "oh yea we will!"

Charles, keep us posted on the loud sound, make sure to clamp that fuel hard-line, and update your first post with items checked off.

M. Requin

Impressive! Great work, guys!! Good to see this mean machine get so well squared away.

BRB-83-911SC

Awesome teamwork. Makes me want to move to Virginia.

cpayne

Thanks. Everyone worked great together.

cpayne

Thanks ! Everyone in the Photo is great and between the three of them you can pretty much fix anything. I play water boy and gopher until I get up to speed.