captcashew

OK, I've had the 928 (1987 automatic S4) long enough to realize I'm going to leak oil. I've had it for 2 years now and it has always leaked a little oil. Not too much, just a few spots here and there, but nothing major. It's been a busy year, so I really have neglected the 928 some this year. Only being able to get out a few times with it, but trying to at least do so for a drive maybe every 2-3 weeks. Nothing too major, but a little.

I've always assumed the leak was from the oil pan or maybe a few other places, but I haven't had the chance to really find it yet. Since the spring though I've noticed that I've had a lot more oil leaking in the drip pan I keep under the engine. Then I finally was able to make it to a PCA event this past Sunday when I was showing someone the engine and actually saw a pool of oil on the engine. See photo below. This was a bit more disconcerting. I'll still research it when I get the chance, but thought this might be a common enough thing that someone could give me a clue about where this particular one was coming from based on where it was pooling near the front of the engine.

Any ideas? As usual, thanks for any tips!

Leon Speed

The oil filler neck warps where it sits on the block. Need a new one. Some people prefer an older metal style. There are many threads about this, including what to replace when you are in there, for example a oil block plate and water bridge seals. Of course, the list is virtually endless if you really like - or need.

Mrmerlin

the oil fill spout is leaking at the base, check for warping
Intake removal is required to get to the spout,
then reseal it with a generous coating of Hondabond 4

captcashew

Ouch. Well, I had been considering doing the intake cover refresh that duane had written up. Didn't think I'd actually have the nerve for it. Seems I may end up trying it anyway. Damn.

captcashew

Does this appear to be the right tutorial?

http://www.dwaynesgarage.norcal928.o...aterbridge.htm

Leon Speed

An intake refresh is very comprehensive and includes the intake (obviously) and cam covers plus other items if so desired. That isn't necessary but recommendable at some point in time. The oil filler neck and water bridge ca be done without the intake refresh and cam covers. That tutorial is the right one. I would recommend installing an oil block plate between the oil filler neck and the block and use older MY gasket, the thick one.

captcashew

Yeah, I'll call 928sRUs and have them send me what I need. I still need to install the replacement fuel line replacement kit they sent me a while back. I've been meaning to do a coolant flush too. And as long as I'm at it, over the winter I had a major power steering leak and was thinking of replacing that hose when I got the chance. That one never seemed to resurface.

I'd like to do the full intake service job, but I was hoping to tackle that over a winter and there is still some driving I want to do this year including the PCA fall leaf drive we were planning on making. We moved into a new house this summer, so making time for the 928 has been pretty few and far between. I think all of the projects I have in mind shouldn't be too bad for a newb like me though. Might make me brave enough to take the intake project this winter.

Any other major leak spots for oil that I might think about doing at the same time?

Bill Ball

That's one way to access the filler neck. Dwayne's full intake refresh is this tutorial.

http://www.dwaynesgarage.norcal928.o...%20Refresh.htm

Not really. Look at the camshaft endcaps and seals, although fixing those leaks are not really related to an intake refresh. The filler neck is the source for oil in the valley and in those wells around the water bridge. Cam cover gaskets often leak, but they leak at the low side, over the exhausts, not into the valley or front of the motor.

marine928

I had discovered same issue (see 07/20/2013 posting "pool of oil on top of engine" while starting my TB/WP service. I have the same model as you and was able to remove the filler cap per the tutorial. Roger has the thicker gasket and I went ahead and pulled the entire water jacket and replaced all the gaskets and rubber seals as well as the thermostat.
There are two rubber gaskets in the thermostat housing and the lower one is a real drag to remove if it is original. It is a metal ring covered by rubber and is pretty well cemented to the housing. Don't be fooled like i was and think it is all rubber.
Since completing everything last week there have been no leaks. I also replaced the PS reservoir and both hoses. There is a filter in the unit and it cannot be serviced. A new res from Roger is inexpensive.

outbackgeorgia

I would be a lot more concerned with the fuel lines. Leaking a little oil is just not the same s leaking a little fuel on the exhaust system.
Install the fuel lines first!
Just my opinion.
Dave