jeff spahn

So I started my intake refresh. It was done 10 years ago but I figured I better do it again so it's good for another 10.


So here it is out. Took my time getting it out and labeling and bagging stuff. Used Dwayne's writeup as guide. Took me about 2 hours to get it out. ISV plug I could get by hand, but it was a tight fit getting in there.

Thanks Rob for the intake sealing plates. You'll get them back eventually!

I haven't lost anything down the intake ports before putting the covers on!
Do you think I needed new knock sensors!

I write down major services on the radiator with a sharpie. When I do it again, just wipe off with alcohol and write it back in.

This hand cleaner is something new I found at Advance Auto. Waterless and ragless. You spray it on, kind of like hair mousse. Rub it in and it dissolves the grease then turns into little flakes and falls on the floor. Doesn't appear to dry my hands out either. Kind of smells like very faint baby powder or something.
Freaky at first but I like it!

I'll get back at it on Sunday. Take the intake apart, replace all the bits that need it and put it back on. But I'll drain and refill the coolant first because I have the kiddie pool underneath to catch everything anyway from the cleaning I'll do.

Gregg K

We belong to a small group around the entire planet, doing this same job. I wonder how many of us there are. 20?

I just realized how cool it is that I live and work in one big room. My espresso machine is in one corner, and the 928 in another.
Cheers.

Dwayne

You're off to a GREAT start! I have got to try the hand cleaner product you found - not that my hands ever get dirty - HA!

I like the idea of writing service info on the radiator - very handy!

jeff spahn

Would not have been anywhere as easy without your write up Dwayne! You provide a very valuable service to the 928 community. If I get back out to Ridgecrest I'll treat you to a butter bar at crest donuts. Was there for the mt Whitney road race about 8 years ago. Got to see the place where they filmed the new planet of the apes. Very neat.

Rob Edwards

Man, you guys are good- I could pull an intake in 2 hours, now that I've done it 3 or 4 times. The first time took at least a full day.

Speedtoys

Ive offered to drive down, bring my smoker, cook for 8-12 people...just for a torque convertor seal and bearing job!



My garage cant do this..I do not have the space..and I have zero level property outside of the very too small garage, and I cant imagine a proper 928 shop charging less than a few thou in labor.

the flyin' scotsman

Surprised to read these are only 10 years old.

They're just going to get worse and if no intention of going back in for another 10 years you may as well replace them.

jeff spahn

That's why I posted the photo. I should have put a smiley face after it. the wire coating on the knock sensors is totally gone

the flyin' scotsman

....and I posted at 2am

The quality of some of these components is pathetic. I have colleagues in the cable manufacturing business........I'll ask what 2011 technolgy has to offer.

jeff spahn

I have noticed that. The materials used in the wiring harness aren't holding up as well as I feel it should. No wonder Ben Burris made a new injection harness out of mil spec stuff.

On another note. I am not going to powder coat the intake. I just don't want to take a chance with blast media being left in there and then have to do a rebuild. Its good enough and looks won't make it run better.

jeff spahn

Well, changed my mind on not powder coating the intake. Having a local tuck pointing shop take the paint of with walnut shells. Was going to have them use baking soda but they feel it would be way, way too slow and cost me $150 just in soda alone.

Going to go with a basic aluminum colored powder coat. Local guy will do the whole intake and cam covers for $30. He does my bikes for $25 (tandem was $75 but he stripped it first). Before the powder coat going to have local plating company dichrome acid pickle the parts to give the powder coat something to really bite on for a tenacious hold.
This should look really nice when done. Might paint the Porsche in yellow and the 32v in red when all done. Have to see how difficult that will be

Speedtoys

Cool..

My gear is all off at the PC and cadmium plating shop, and the weekend of the 15th is go back together time.



Yup..I can taste that im payin far too much for pretty..but hey...why not.


Will have another small batch to get cad plated when I do the WP/TB job later this winter...but I probly wont start that job until Roger has a cam gear alternative and pricing ready to ship.

I'll do caliper refresh, Bilstein install...dangit..a great # of things should come off for media blasting or coating in the suspension....this was an Ohio car and nobody cared.

jeff spahn

I found two things when WYAIT got a hold of me tonight. I was cleaning the alternator, took it off, and pulled off the oil pressure (?) sensor plug.
I see the wires can touch because the insulation has broken down on the wires.
I guess my first question is: can I just put liquid electrical tape on it and call it good or is there a new plug I can install by cutting off the existing one and soldering a new one on.


My next find was this shock collar:

I was cleaning and figured why not clean the upper a arms since I put in new ball joint covers. Didn't see it then. Guess I got a little too happy adjusting my suspension up to get to factory ride height (have new Eibachs).
I am gonna have the shop that is putting a new high flow system on my explorer tomorrow take the shock apart and rethread the collar back down on. If it is messed up, I hope I can buy a new threaded collar.

The whole cleaning process can get away from you. So I decided to check my cam gears.
Passenger side looks good. Lightness on gears is the flash, they are uniform in color.

and drivers side:


Then I got to looking at the chain tensioner for the cams.

Hardly any groove in it. It can stay the way it is.

This is really fun. Hope you guys can give me suggestions on the oil pressure plug. I'd like to solder in a new one if possible. Otherwise the liquid tape it is.

Speedtoys

Have you ordered the replacement cam oil feed plugs in the back of the head since yer open?

cjn928

My garage cant do this..I do not have the space..and I have zero level property outside of the very too small garage, and I cant imagine a proper 928 shop charging less than a few thou in labor. [/QUOTE]

I'm having a trusted 928 shop do the intake refresh and motor mounts, pan gasket.
It should run me $2500 including parts and powder coating.
I read Dwayne's write up a few times as a bed time story...
He made it look too easy, I opened the hood a couple of times....