Jdinark

86.5 with 56k miles. About to replace vaccum hoses. Should I go ahead and do an entire top end refresh ? What does that involve ? Is it something a competent mechanic can handle or should it go to a 928 specialist? If so what should I expect to pay ?

Thanks !

Adamant1971

So many variables, but if you do a full intake refresh, parts will be about 1k. If you powdercoat all the bits add 300-500 hundred.

If you can turn a wrench and follow directions you can do it. Read everything in the link below, it's on 87 but will give you the gist.

http://dwaynesgarage.norcal928.org/1...%20Refresh.htm

SMTCapeCod

Hi,

I picked up my 86.5 a couple years ago with about 10K more miles, also in great condition. I'm usually all about fixing-what is or might-be-broke, rather than the wholesale system revamp that other folks opt in for. Nevertheless, my recommendation in this case is yes- do the whole deal.

It is a bit of an operation to get the intake out of the way to check the lower vac hoses that are ported to points under the throttle body. Some of the electrical connections may be toast (esp the little harness for the TPS) and so too the connectors for the vacuum lines. You've already heard about the fuel lines. So I came to my realization slowly and that stretched the project a few days, but I'd recommend considering whether or not you want to powder coat the manifold (if there are cracks in the factory coating, it is probably getting ready to start flaking off), getting fresh o-rings for injectors, resealing throttle body and replace any broken rubber mounts, vac lines, fuel lines. And think about whether precautionary replacement of throttle position sensor and aux air intake makes sense for your personal circumstances. They both fail with some regularity and would require pulling the manifold again.
And also, if you haven't yet search the forum for the thread on "Porken"'s S3 specific performance chips and if you have any interest, now might be a good time to do that for ease of the requisite fuel pressure regulator change. Of course, you may want more of a baseline on the car before bumping the timing, etc. Make sure you count o-rings at the MAF and compare to factory diagram, one of the sealing rings is often missing.

If it's a goood mechanic there should be no problems, nothing especially tricky though many of us have been burned rolling with those reasonable assumptions. Always better off with someone with bona-fide 928 knowledge and enthusiasm, that has some foresight on the gotchas. If they roll their eyes when you roll in and tell them what you've brought make/model, run.

Wisconsin Joe

Here is a very detailed thread of an Intake Refresh on an 86.5:

https://rennlist.com/forums/928-foru...rst-timer.html

linderpat

I did that job on my prior 86.5, and it wasn't too bad if you follow all the advice on this forum. To have a mechanic do it would be cost prohibitive - many thousands, and no way would the work be as good in the details as what you would do ( at least as to me).

syoo8

Hi JD,

Where do you live? If you live near Sean Ratts (Dallas) or Greg Brown (Anaheim) or Stan (Philadelphia)- or the other 928 "greats" - they might be able to do an intake refresh quickly, and well.

You might want to contact Roger Tyson at 928sRUs. He has a list of the 'bare minimum' you need to do an intake refresh but also the 'premium package' of everything you need to change, 'while you are in there.' I went with the 'premium package'- changing every boot, hose, sensor, etc in sight. It cost me more like $2000 when it was all done in parts, plus another $1000 in tools (I didn't have many before the job), plus $700 for powder coating.

For powder coating I went with Legend Garage in Austin, and the owner Ben Genovese does impeccable work. He specializes in our cars. Roger recommended him as well.

The thing about this job- doing it for the first time is very slow, but who will do it for a second time?

I'd say do it yourself- it is a lot of fun in the end.