Dash work

Replaced the lcd screen on the clock, and upgraded the backlight with a white led.

The odometer gear will be replaced when the new one arrives. Note the orange teeth that have broken off.

Out with the old...

In with the new.

Quite a pain to remove the rusted hatch pin. Days in penetrant.... and it still broke...... about 5 times. In the end I had a hand full of chunks, and the shank was still in the mounting nut (that is very difficult to source), so..... I drilled through it and tapped new threads. A bit unorthodox, but it looks like it worked.

The new pins I bought are stainless steel, so they should hold up. I originally planned on making my own, but these are very nice, and at a good price too.

More paint...

Decided to paint the idle control valve bracket, and replace the orange wire clips, with proper Adel clamps.
I also riveted some anchor nuts to facilitate clamp installation, and replaced the broken vibration isolating studs. Note the light weight, last a lifetime, titanium screws.......Nothing but the best.

Unfortunately once I install the intake manifold, no one will ever see this.

Some painting

A bit of cam tower restoration...... With PORSCHE written in 3x6 cm letters, it's the first thing one notices when looking under the hood of a 8V 944.

Shifter

The pin (circled in red) on the shift lever tends to wear in an hourglass shape due to the side to side movement needed to shift in gears 1, 2, 5 and reverse.

 I am also missing the original shift knob. A non-standard rectangular receptacle is needed to attach the shift knob.  In order to solve both of there problems, I made a shift lever with a replaceable bronze bushing, and threaded cylindrical shaft.

Balance shaft reseal

While resealing the AOS, I noticed that the rear plug on the upper balance shaft was loose. The o-ring has shrunk significantly in its 25 year life. I replaced the o-rings on both shafts, and resealed the covers with the factory recommended Loctite 574.

Oil in intake

The air oil separator (AOS) seals are the cause of oil ingestion. The filler neck is attached to a canister (AOS) that is under vacuum.

The seals have been replaced!

Front seals.

On the 944 we have 4 front shaft seals. The crank seal (front main seal), cam seal, and two balance shaft seals. They were leaking pretty bad.

Unfortunately I only took one picture, of the freshly resealed front.

Oil cooler

Courtesy of the previous mechanic, the oil cooler spigot was bent, causing oil/coolant mixture, and the threads for the OPRV (oil pressure relief valve), were quite mangled. No wonder it was leaking oil, quite vigorously.

I had to replace the housing and the oil cooler. This it the difference between the early and late housings.
The raised boss, was trimmed flush, and replaced with a plastic washer on the oil cooler end.

The new (to me) oil cooler being leak checked prior to installation.

Picture time!

Built a tent on January first 2012. My lovely wife helped with the tarp installation.

First task was to replace the output shaft seals on the transaxle, and repack the CV joints.

Notice the washer in the second picture... it is installed backwards.

Black and tan in the third picture, along with a freshly packed joint in the background.

Problems

Problems:

Alternator did not charge

E-brake did not work

Hatch release button inoperative

Oil seeped from every pore

Oil in expansion tank

Broken front left signal

Power steering pump spewing ATF, and missing tensioner replace with a brutal looking $2 turnbuckle.

Missing: protective engine shield, AC knob, spare tire, jack

Sheared AC compressor bolts

Oil in intake

Broken Driver's door handle, actuating lever, and electric actuator linkage

Broken Passenger's door electric actuator linkage, and inoperative door handle

Timing and balance belts and rollers worn

Alternator and power steering belts brittle

All coolant hoses brittle

Cracked fog light

Inoperative horn

Oil and water soaked carpet, and insulation

Passenger's seat slider lever broken

Inoperative mirror switch

Cracked windshield

Dented nose panel

and the list probably goes on......