StratfordShark

Am in middle of MM job so wanted to renew pan gasket (weeping more than leaking in areas where gasket is extruding - nothing serious but want to do while things apart).

Crossmember is out and alternator lowered. I know I have to remove starter, but does anything else need to come apart on my 91 S4? If it's a long list of extra brackets I may just snug the bolts!

Oh and I have 10mm gear wrench...

Thanks

Adrian

Leon Speed

I don't recall having to remove the starter, or is that a RHD thing. If the cross member is out nothing more is needed. The seal does touch the oil filter a bit so you want to remove that but you will need a new filter anyway. Maybe remove and clean the oil pressure sender, then you need a new aluminum crush seal.

StratfordShark

Thanks Aryan. I forgot to say filter off too as drained oil before starting MM.

Some bolts are tight to the sender which is oily at top (don't know if from gasket or the sender seal washer), but I can't shift the connector to sender and am nervous of breaking it as such an odd plug. I understand plug needs to be off so as not to twist wiring when undoing sender nut.

I'll have another go at the connector - it would be good to give plan thorough clean.

Schocki

Starter has to come out, otherwise you can't drop the oilpan. Replace the steering rack bushings with a set of DELRIN bushings from Roger.
If you like to take your 928 to the track an oil pan baffle would be a good idea. They are standard in the GTS... But this is optional.

StratfordShark

Nice photos Schocki and thanks.

I would just embarrass myself on track so no baffle required...

I did order set of rack bushings, but then remembered Porsche fitted brand new one in 2000 for previous owner. Only has about 15,000 miles on it so the bushings I mangled removing were probably fine! Oh well at least Delrin ones are immune to oil etc

Bertrand Daoust

This would be the perfect time to change your motor mounts if not already done.

https://rennlist.com/forums/928-foru...-tomorrow.html

Thanks Dwayne.

StratfordShark

Bertrand that's good idea but this whole project started with motor mounts and has mission crept ever since! New rack bushes, tie rods, shocks, springs, PS lines....

I'm losing courage about changing the gasket though. There are some very awkward looking bolts right at front of the pan - hard enough to get light on them let alone a wrench, as not much room to get a good look with fan shroud in place and the a/c compressor on right side.

There's a connector going into top of front left pan (oil temp sensor?). How do you deal with this even with all pan bolts off? No way to remove it before as it's pretty hidden up there.

The car is on high stands. Do people ever do the OPG job on stands or is it more of an engine out thing?

Bilal928S4

I have done my MM/OPG projects on jack stands for both my cars. The sensor wire just pulls off the sensor. You do not have to take the sensor off the oil pan. Be careful of the connector cover as it is usually brittle and will crack. That connector cover is NLA.
As you are there I would strongly suggest replacing the OPG.

StratfordShark

That's encouraging Bilal thank you. If that sensor wire just pull off then sounds much easier.

Bilal928S4

On Schocki's third picture you can see the sensor is still installed and the connector is off. I followed Dwayne's excellent write up and had no problems.
The only thing I did differently was hand tightened all the OP bolts and then when they were snug, took one out at a time and put some blue locktite on each one and then snugged them with a gear wrench.

StratfordShark

Dwayne's write-ups are my bible but I don't see one for OPG? Looking at Dwayne's Garage site.

Can see the sensor in the photo but do you or anyone have photo of how connector attaches? I can get hand on the rubber boot and feel a wire inside but don't want to risk severing wire by pulling wrong direction. I'm pulling straight up and boot stretches but nothing comes off!


EDIT: a little search revealed it!s tube onto pin under boot. I'll have another look at it with boot peeled back - mine is nice and supple

Bilal928S4

It pulls up off the shaft of the sensor. To facilitate you can put a small screw driver and twist it to get the connector to snap off.
Yes, you are correct Dwayne only has a motor mount write up. Will have to research where I got the OPG write up or just did it by feel.

Gary Knox

The oil level connector cover WAS available when I did much of this a few years back, but NOT as a 928 part. I found it in PET under 944 parts. Anyone who has one that is 'toast' like most are, might look in the 944 parts catalog.

StratfordShark

Some progress, some problems.

Got the starter off. The allen boots are a pain as no room behind them for ratchet head and allen sockets. But they broke torque (quite the crack from one of them) with long allen key inserted and the tube of bottle jack handle over it for some extra leverage. The starter came out with a bit of jiggling.

I couldnt make progress with removing sensor connector so decided to leave one till I can lower pan and have better access to it.

Tackled the least accessible bolts first at front of pan. They are a nightmare! I got them started with gear wrench, then have to contort myself to get fingers on them to unscw all the way. Putting them back will be interesting. Would make it easier to remove a/c belt? It does get in the way in that very small gap, plus I don't like getting grease on it from my hands (it's the leakiest part of gasket somoily round there)

Anyway I have 3 of 4 most tricky bolts out and called it a day. The others should be a breeze.

Do any of you have some secret for getting at those front bolts? I dont have big hands and it's really awkward for me. Do youjust employ child labour to get at them?

Bilal928S4

Nope, you just get used to having your hands in awkward positions.