Replacing the fuel pump without dropping the tank *pics* (4th Gen F-bodies)
Model : Pontiac, Firebird Category : Fuel System
... hassle of needing to drop the tank?! Finished! Almost... More pics of finished product.... __________________ For all your web and graphic design needs... _______________ 2002 SOM Trans Am WS.6 MODS: Eibach Pro's, SLP LM, Toyo Proxes T1-S, big surprise to be unveiled at Bowling Green... masterofdragons View Public Profile Send a private message to masterofdragons Send email to masterofdragons ... (more)
Posted : 9 June 2005  
 
356 Valve Adjustment
Model : Porsche, 356 - Series Category : Engine
... the engine until it reaches top-dead-center (TDC) for cylinder number 1. Remove the distributor cap so that you can see the location of the rotor. Rotate the engine by turning the generator pully as shown in Figure 2. There should be a small notch on the edge of the distributor, indicating TDC, cylinder #1. Once the rotor is in the general vicinity of the notch, line up the crankshaft pully ... (more)
Posted : 6 June 2005  
 
Converting A Mechanical Tachometer to Electric
Model : Porsche, 356 - Series Category : Interior
... steering wheel, see the technical article, Removing and Replacing a Porsche Steering Wheel. After the wheel is removed, then loosen the two steering column retaining bolts on the bottom of the steering column. At this time, you should be able to drop the column down far enough to remove the tachometer from the dash. Depending on how long its been since the gauge was last removed, it may require ... (more)
Posted : 6 June 2005  
 
Replacing 356 Axle Boots
Model : Porsche, 356 - Series Category : Driveterrain
... Axle boots are generally pretty cheap (approximately $20 for the pair). Here's a more detailed list of what you will need:Two Axle BootsAbout a gallon of Transmission Gear OilGear oil pump for filling the transmission In order to replace and install the boots, the axles need to be supported evenly, as if the car were sitting on the ground. This makes the job ideal for using drive-up ... (more)
Posted : 6 June 2005  
 
996/Boxster Bra Installation
Model : Porsche, Boxster Category : Interior
... you may wish to “roll” the front of this piece down slightly so the felt edging is not exposed when the hood is closed (Figure 3). The bumper piece has one small hook in the center with a cylindrical retainer on each side. These two retainers fit into the space between the hood and the top of the bumper cover when the hood is closed (Figure 4). Fasten the small hook in the ... (more)
Posted : 6 June 2005  
 
Boxster Door Sill Installation
Model : Porsche, Boxster Category : Interior
... complement to the Boxster appearance. We also have them in carbon fiber, for a unique high-tech look. On either stainless or carbon fiber, the Boxster logo is subtly understated. The pictures don’t really do the stainless steel sills justice—they are hard to photograph. When you buy your door sills from Pelican Parts, you can rest assured that these are the genuine article, made in ... (more)
Posted : 6 June 2005  
 
Porsche Boxster Litronic Headlamp Kit Installation
Model : Porsche, Boxster Category : Lights
... that is the highbeam rotation. The module is supposed to rotate the normal beams up 1.5 degrees to augment the high beams when they are activated. This fills in the light below the high beams a bit better. Installing the control module is relatively simple, but does require some modest confidence working with electrical wiring. These litronics differ from the factory installed ones in two ... (more)
Posted : 6 June 2005  
 
Roof Transport System Installation
Model : Porsche, Boxster Category : Exterior
... pricey, about $500 or so, but I'm sure will prove invaluable in time.I bought the RTS to go with my new Boxster, and found that the installation instructions that come with it are a bit lacking. It's not hard to install, but parts of it are confusing. With a Porsche, one can be nervous about doing something to ruin the car.I'd like to recommend another option to any boxster owners out there. If ... (more)
Posted : 6 June 2005  
 
Jacking Up Your Boxster or 996
Model : Porsche, Boxster Category : Misc
... I get under it. The Boxster or 996 requires a slightly different approach to jack it up. The jack points are oval-shaped sockets in the bottom of the car, and the underside of the car doesn’t have any obvious places to put jack stands. Pelican Parts now offers a custom floor jack adapter, specifically for the Boxster and 996, which allows the car to be jacked up safely. It comes in a nice ... (more)
Posted : 6 June 2005  
 
Modifying the Boxster OBC
Model : Porsche, Boxster Category : Electrical
... stay in place. Optional: Use the Ohm Meter to test the wires. Disconnect the battery. Lower the windows, lower the top, open the front trunk. Remove the key from the ignition. Remove the battery cover by twisting the screws 90 degrees. Use the 10mm socket to disconnect the negative terminal. 3. Remove Instrument Cluster Pry out the microphone cover with a small screwdriver. Pry out the hazard ... (more)
Posted : 6 June 2005  
 
Installing your own Boxster Rear Speakers
Model : Porsche, Boxster Category : Electrical - Radio
... any different than they are, I just hope these pictures make the process easier for you. For your reference the two most useful posts are: http://www.iq.dynip.com/~gary/index.cgi/index.cgi?read=595http://www.iq.dynip.com/~gary/index.cgi/index.cgi?read=629Before proceeding, you will need the following: Wiring harness from Becker (part number 1163.736-276) Radio removal tool from Becker (part ... (more)
Posted : 6 June 2005  
 
Boxster Oil Change
Model : Porsche, Boxster Category : Misc
... a plastic housing with a replaceable paper cartridge. This plastic housing is meant to be reused indefinitely, so don’t use pliers or any other tools for removal that might pierce or crack the housing. To begin, jack up the car, and use safety stands. Make sure it is secure, because you will be working underneath. For the correct way to jack up your Boxster, see ... (more)
Posted : 6 June 2005  
 
944 Sunroof Operation
Model : Porsche, 944 - Series Category : Interior - Sunroof
... wires Installing Sunroof Gears Part NumbersPart Part Number Plastic Sunroof Gear (Feb. 1986 - 1991) 944-564-430-01 ProcedureThe first step in replacing the plastic gears in the late model 944 sunroof is to determine whether one or both of the gears are stripped. If only one of the gears is stripped, it simplifies the replacement process. The gear which has not been stripped can be use as a ... (more)
Posted : 6 June 2005  
 
944 Stereo System Update Cassette to CD
Model : Porsche, 944 - Series Category : Electrical - Radio
... Figure 4). If the tools are difficult to insert through the holes in the faceplate as mine were, file the smashed down area - about " from the tool’s ends where the excess material is squished out to make the catches - until they’re round.STEP THREE – Label the connections As you look at the rear of the Monterey, you’ll notice that all connection except the antenna ... (more)
Posted : 6 June 2005  
 
944 2nd Taillight
Model : Porsche, 944 - Series Category : Lights - Tail lights
... you may also try popping one from the tail light assembly and trying at an auto parts store. **AND** 2 x female spade connectors ****OR**** Soldering Iron 2 x hose clampsInstallation: Same for each side 1. Disconnect the wires from the tail light assembly. 2. Unscrew the cover, remove the metal plate with the light bulbs from the cover. 3. You now have a metal plate with 4 light bulbs on ... (more)
Posted : 6 June 2005  
 
Solving Strange 944 Gauge Problems
Model : Porsche, 944 - Series Category : Interior
... it as a whole assembly – prepare to spend in the neighborhood of $1500 or more if you screw up. Of course, if you screw up, I am not responsible, you have been warned. Tools: 24mm Socket (for steering wheel) Phillips Screwdriver Flathead Screwdriver 5, 6, &7 mm sockets metal polish (Never dull works great) alcohol wipes (or alcohol and q-tips) Light bulbs (available from Pelican) ... (more)
Posted : 6 June 2005  
 
944 Door/Handle/Latch Tune-Up
Model : Porsche, 944 - Series Category : Interior
... WD-40. 5. Spray hinges and door stop assembly with WD-40 6. Lube latch assembly on door, hinges, and doorstop with white lithium grease, lubricate locks with graphite. 7. WD-40 and Lithium grease on window actuator arms (the scissor arm assembly that the glass mounts to) or crank assembly (non-power windows). 8. NOTE: This part is OPTIONAL. A. Remove the plastic sheeting from the inner door ... (more)
Posted : 6 June 2005  
 
944 Rear Hatch Glass Repair
Model : Porsche, 944 - Series Category : Interior
... Loosen all 4 bolts but do not remove. Remove the retaining clips on the hatch struts and disconnect the wires for the defroster and wiper motor if equipped. With the help of an assistant, (have them support the hatch while the bolts are removed) remove hinge bolts and washer plate under the bolts. Disconnect the hatch struts and CAREFULLY lift the hatch off the vehicle. Pretty strait forward. ... (more)
Posted : 6 June 2005  
 
Installation of 968 Mirrors On a 1986 944 Turbo
Model : Porsche, 944 - Series Category : Interior - Mirror
... which wire goes where you can plug them in and make sure it’s doing what it’s supposed to. If for some reason you would like to remove the glass (perhaps to get better acquainted with the wiring of your motor) Note- the small bulb sticking out the bottom of the mirror in between the two arrows was some sort of light, I am not sure what it is used for, I suspect it is to tell the ... (more)
Posted : 6 June 2005  
 
Cleaning & Rebuilding 944 Fuel Injectors
Model : Porsche, 944 - Series Category : Fuel System
... from the car, you can flip it upside down and rest it on the shock tower. 11. Using your drip pan and the adjustable wrench, loosen the large bolt on the front of the fuel rail and drain the fuel from the rail (NOTE: if you have to remove the bolt, DO NOT lose the sealing ball inside the bolt) 12. Pry the retaining clips off of the injectors 13. Grasp the injector and pull it out of the fuel ... (more)
Posted : 6 June 2005  
 
Changing a 944 Thermostat
Model : Porsche, 944 - Series Category : Engine - Cooling System
... continue – your hoses will thank you. OPTIONAL: Disconnect the upper radiator to engine hose at the radiator. Take a garden hose and hold it in the lower radiator outlet and turn on the water. This back-flushes the radiator and should remove any clogs you may have. 9. Optional: If the water pump/radiator hose connection has a bunch of crud on the outside, you can remove it with a rag and ... (more)
Posted : 6 June 2005  
 
Rogers Racing: How I do It (Race a 1973 Porsche 914)
Model : Porsche, 914 - Series Category : Misc
... for wheel to wheel racing. Use kevlar lined fuel lines and barbed fittings. - Fire bottle with three outlets and pull handle in the driver’s reach. Hope I never have to use it! - BMW 320I calipers and stock rotors front/rear, tee in place of the prop valve, 23 mm master cylinder, ATE blue brake fluid, Metal Master pads. Cooling air to the front brakes and I have pretty darn good ... (more)
Posted : 6 June 2005  
 
914 Alternator Replacement
Model : Porsche, 914 - Series Category : Electrical - Alternator
... Craftsman screwdriver I could find—the normal-sized ones chewed up the screw-heads pretty badly. Also loosen the hose clamp that holds the hose from the heater fan onto the left-side heat exchanger, and pull the hose loose from the pipe. Now lift and support the car. From underneath, remove the nut that holds the BIG black wire onto the end of the starter. There is a smaller red wire on ... (more)
Posted : 6 June 2005  
 
914 Headlamp Motor Troubleshooting
Model : Porsche, 914 - Series Category : Electrical
... motor control relay from it’s socket and set it aside. CAUTION!!! Be sure that the relay has been removed from it’s socket before making this test!! If you fail to do this, you will fry the relay!! If both headlights are affected, it does not matter which one you choose for this test, otherwise, choose the defective one of course. Now take a reasonably good size jumper or clip ... (more)
Posted : 6 June 2005  
 
Replacing the Turn Signal and Wiper Switches on a 914 Autocross Car
Model : Porsche, 914 - Series Category : Electrical
... on off on, for the wiper switch. Note: The (on) means the switch is MONENTARY or you have to hold it. Here are the steps to complete the job, some may be done in another order, but this worked for me.Remove the batt. ground connection.Remove the knee gaurd as per chapter 10 (so I wouldn't damage it only).Remove the steering wheel (if you have a push-to-talk switch, be careful).Remove the ... (more)
Posted : 6 June 2005  
 
Replacing the 914 Ignition Switch
Model : Porsche, 914 - Series Category : Electrical - Ignition
... remove the knee pad from underneath the dash board. This is held on with screws both underneath the dash, and on the sides. The screws on the side of the knee pad are normally hidden by plastic covers that need to be removed before you can remove the retaining screws. The left side retaining screw is shown in Figure 4. After both side screws are removed, (you may need some needle nose pliers ... (more)
Posted : 6 June 2005  
 
Alternator System Troubleshooting
Model : Porsche, 914 - Series Category : Electrical - Alternator
... field is what the alternator needs to start up, and if everything is working correctly, that's exactly what happens. The alternator now begins to develop identical voltages at the D+ and B+ terminals. The D+ terminal is connected to one end of the charge warning lamp, while the other end of the lamp is connected to the battery via the ignition switch. Since the B+ terminal is hard-wired to the ... (more)
Posted : 6 June 2005  
 
Headlight Switch Internals/Repair
Model : Porsche, 914 - Series Category : Lights - Headlights
... that the rheostat assembly is electrically separate from the switch part. OK, let's finish disassembly. Carefully lift off the contact slider block from the shaft. There are two small springs in the bottom of the switch that push the plastic pins down - they may fall off into the switch body. Leave them there until later. Put the slider block aside. Pull the shaft out of the rheostat, and put it ... (more)
Posted : 6 June 2005  
 
914 Restoration of Pedal Box Floor Area
Model : Porsche, 914 - Series Category : Interior
... part, or fabrication of a new structure. I choose fabrication, from flat stock. Measure the rectangular hole you just cut, and begin by laying out a flat piece for the floorpan, sized to fit as appropriate for MIGing in place with 1/16" gap all around to allow weld penetration and expansion. Fabricate the stiffener from drawings made from original. Cut and size a single piece for bending ... (more)
Posted : 6 June 2005  
 
Fabricating 914 Seat Brackets
Model : Porsche, 914 - Series Category : Interior
... cutting a straight line with a hacksaw, line up your cut with the vice jaws and use them as a guide for the blade. Now take the block of wood and center it on the parallel lines going the long direction. Place this in the vice so that the wood is flush with the vice jaws and bend the metal to a 90 degree angle over the wood. Now turn it over and do the same thing on the other side. Take the wood ... (more)
Posted : 6 June 2005  
 
The 914 Center Tunnel
Model : Porsche, 914 - Series Category : Interior
... the panel that is facing toward us is part of the firewall of the donor 914. The plastic fuel lines, the metal brake line, and the metal tubes for the various control cables are visible. In the second picture, we see the rear half of the tunnel. This view is as if we were laying underneath the car, looking up, with our feet toward the nose of the car. The two curved tubes toward the left side ... (more)
Posted : 6 June 2005  
 
914 Fiberglass Flare Installation Tips
Model : Porsche, 914 - Series Category : Misc
... to the body as possible. > >Now take a scribe and outline the edge of the flare into paint on the >fender. Remove the flare. Now follow the inside edge of the scribe with a >strip of 3/4-in masking tape. Now follow the inside edge of the masking >tape with another strip of 3/4-in masking tape. This will give you a 1 1/2 >-in border inside the scribe mark. This will be your cut ... (more)
Posted : 6 June 2005  
 
Five-Lug Rear Wheel Conversion
Model : Porsche, 914 - Series Category : Suspension
... Bee Jay pushed the inner CV joint into on the right side. So, disconnect the battery ground, disconnect the cables to the starter, and remove the starter. You now have enough space to push the inner CV joint up and forward, and the stub axle will clear the trailing arm. Bee Jay believes removing the starter is a lot less hassle than dropping the exhaust system. Decide for yourself.Figure ... (more)
Posted : 6 June 2005  
 
914 Five Bolt Pattern Conversion Guide
Model : Porsche, 914 - Series Category : Suspension
... steering rack (all 911s, 912s, and 914s used the same steering rack). A built in sway bar.A lighter, aluminum steering rack mount (on the later suspensions)Larger torsion bars (19mm vs. 18mm).Larger brakes.You will need the larger 19mm master cylinder. Figure 5 and Figure 6 show a 914-6 front end with vented brake discs, and 'M' calipers.See article on 911 Front Suspension Spotter's Guide. ... (more)
Posted : 6 June 2005  
 
Installing a 914 Rear Sway Bar
Model : Porsche, 914 - Series Category : Suspension
... The 'raised' portion of the sway bar actually mounts to the rear trunk sheet metal. The proper location of the sway bar mount is shown in Figure 3. Once this location is identified, it is recommended that you score the location on the sheet metal with a sharp object. The bracket will need to be welded onto the transmission support bar, and the trunk floor. Before doing this, however, it is wise ... (more)
Posted : 6 June 2005  
 
Installing the 914 Center Console
Model : Porsche, 914 - Series Category : Interior
... you are ready to install the center console unit on top of the center tunnel. Start by replacing the carpet in the center tunnel. You don't need to reglue the carpet, since the console itself does a pretty good job of holding down the carpet. Don't reinstall the rubber boot on the shift lever - you don't need it anymore. Make sure that you pull the lead wire (blue) for the defroster lamp, and ... (more)
Posted : 6 June 2005  
 
Race Seat & Harness Install
Model : Porsche, 914 - Series Category : Interior - Seats
... high quality.[Click on thumbnails for a larger view] Corbeau Forza seats (I got black) 914 adapter rails The seat base FIA approval Unfortunately, the holes in the brackets were off by about 1/2", so I had to drill an additional hole in one end of each rail to get the necessary spacing. I actually did this on the "front" of the rails on one seat and the "back" on the ... (more)
Posted : 6 June 2005  
 
Mounting A Race Seat In a 914
Model : Porsche, 914 - Series Category : Interior - Seats
... seat in place, sitting on some phone books or anything that will support it and climb in to see how it feels. If you have a cage with door bar like I do, getting in and out is much easier with a removable steering wheel. 9. Once the position feels good, have someone measure the distance from the top and bottom of the seat to the firewall, save these measurements and then remove the seat. 10. I ... (more)
Posted : 6 June 2005  
 
Adding a Second Hot Air Blower Motor to the 914
Model : Porsche, 914 - Series Category : Interior - Heating and Air Conditioning
... rebuild it, not too hard, just had to clean up the contacts a bit. Then I went down to the local Pep Boys and bought three and a half feet of heater hose. This stuff is only about a dollar a foot. I took the factory end cap off the heater attachment inside the engine bay on the right side, then installed the hose with a hose clamp on to the attachment. I then mounted the fan with some plumbers ... (more)
Posted : 6 June 2005  
 
High Output Twin TurboFan 914 Heater Defroster Booster System
Model : Porsche, 914 - Series Category : Misc
... this. Drill the appropriate size holes for the mounting screws. Cut a 8 section of dryer hose and attach it to the end of the fan with a hose clamp and seal it with the aluminum tape. Make sure that you attach it to the side that the air will be drawn from, this can be determined by the direction of flow arrow atop the fan. Make a 90 degree bend in the dryer hose and then trim it to the correct ... (more)
Posted : 6 June 2005  
 
914 Wheel Types
Model : Porsche, 914 - Series Category : Wheels and Tires
... This is a 4- bolt Mahle wheel. Factory option from 73-76. In 1974, these were stock on all Limited Edition cars and were painted to match the trim (yellow, orange or green). It sounds ugly, but looks cool. Thanks, Perry Kiehl, for the picture. Personally, my favorite 914 stock wheel, the Pedrini. The Pedrini was a 4-bolt alloy wheel offered from 70-72, and at first glance is very ... (more)
Posted : 6 June 2005  
 
914 Outer Door Handle Replacement
Model : Porsche, 914 - Series Category : Exterior
... This bolt is shown in Figure 5. Make sure that you don’t drop it down into the door, as it is sometimes difficult to recover nuts and bolts from the inside-bottom of the door. After you remove the bolt on the inside, remove the nut that holds the other end of the door handle on the outside of the door. This nut is shown in Figure 6.After the nut is removed, you can remove the door ... (more)
Posted : 6 June 2005  
 
914 Ski / Bike Rack Installation
Model : Porsche, 914 - Series Category : Exterior
... console replacement. I would like to add my 2 cents to the bike-rack needs of my fellow 914’ers. I have long-since used a particular rack on all of my old cars which have rain-gutters. Like my 1966 Dodge Charger, 1969 Volkswagen Beetle and my late model Audi. This rack works very simply by having a narrow "foot" which sits in the rain-gutter and has a plastic-coated metal ... (more)
Posted : 6 June 2005  
 
Installing the Passenger Side Mirror on a 914
Model : Porsche, 914 - Series Category : Exterior - Mirrors
... Holes Drilled Through Door SkinFigure 8: 914 Mirror Shown Installed on Right SideRemoving the Door Panel To remove the door panel, you first need to remove the lower part of the passenger arm rest. Three screws are used to hold this section in place. The three screws can be seen in Figure 2. After removing the screws, slide the bottom piece towards the rear of the car to remove it from the ... (more)
Posted : 6 June 2005  
 
Installing a 914 Hood Crest
Model : Porsche, 914 - Series Category : Exterior - Hood
... the 914 crest. The first step is to get the Hood Crest Kit. The kit includes the crest, the seal that goes underneath the crest, and two mounting clips. Pelican Parts has very competitive prices on this kit and other parts for your 914. To find out the current price of the 914 Hood Crest Kit, please see the Exterior Trim section in our 914 On-line Catalog. The next step is to print out ... (more)
Posted : 6 June 2005  
 
Electronic Fuel Injection (EFI) Troubleshooting Document #1
Model : Porsche, 914 - Series Category : Fuel System
... starter is running. Replace pressure regulator if necessary. Defective diaphragm chamber in pressure sensor. Replace pressure sensor. Engine starts when cold but stops again. Wire connector for trigger contacts in distributor not connected or wire broken. Connect tester and go through test steps 8,9, 10, 11, 11a (EFAW-tester) resp. 14 (VW1218). If necessary, replace wire harness or trigger ... (more)
Posted : 6 June 2005  
 
Ignition Troubleshooting
Model : Porsche, 914 - Series Category : Electrical - Ignition
... our spark plugs, and that’s basically all there is to it. Now to practical matters: First, the condenser. This name is a holdover from the 1920’s when all capacitors were called "condensers". The one on the side of the distributor is a capacitor too. A capacitor’s job is to store energy in the form of electric charge. I won’t go into as much detail as I did for the ... (more)
Posted : 6 June 2005  
 
Installing and Adjusting New 914 Brake Pads
Model : Porsche, 914 - Series Category : Brakes
... front or rear brakes. Details on bleeding the 914 system can be found in the Pelican Technical Article, 914 Brake Bleeding. Replacing Rear Pads The front pad replacement is easy compared to the rears. The addition of the parking brakes seems like an afterthought with the design of the 914 calipers. Because of the parking brake and it's action on the rear pad, you need to manually set the ... (more)
Posted : 5 June 2005  
 
Bleeding 914 Brakes
Model : Porsche, 914 - Series Category : Brakes
... right rear caliper, the one that's located furthest away from the master cylinder. You will have to remove the rear wheels of the car to easily get to the rear caliper. The front wheels can be turned for access to the calipers. Bleed the right rear caliper by attaching a hose to the bleed nipple, placing it in a jar, and then opening the valve with a 7mm wrench. A bleeder nipple is shown in ... (more)
Posted : 5 June 2005  
 
Replacing 914 Rear Calipers
Model : Porsche, 914 - Series Category : Brakes
... we recommend is called EZ Bleed, and we are currently trying to locate the manufacturer to supply it to our customers. You can also use a vacuum bleeder, or a family member to pump on the brake pedal until the system is dry. We don't recommend the family member approach, as you will have to pay them pay in extra favors later on... With your preferred method of bleeding, empty the system of ... (more)
Posted : 5 June 2005  
 
Hydraulic System Concerns in 914-4 Front Brake Upgrades
Model : Porsche, 914 - Series Category : Brakes
... REALLY big brakes with four piston calipers. As part of the brake biasing, rear calipers usually have smaller pads and smaller diameter pistons than front calipers. Our original equation was: Pressure = Force divided by Area To calculate the force being applied to the caliper pistons we rearrange the equation to read: Force = Pressure times AreaAnd in this case the area being used is ... (more)
Posted : 5 June 2005  
 
Upgrading the 914-4’s Front Brake Calipers to BMW 320i Units
Model : Porsche, 914 - Series Category : Brakes
... be confused as to which flange faces (the inside ones) need to be machined. Your calipers may have a recognizable casting mark that is just about at 0.125" from the face to be machined. NOTE: Before machining the 320i calipers, you should verify (with an accurate measuring device, e.g. dial caliper or micrometer) that the two mounting flanges are equally thick. If they are, follow the ... (more)
Posted : 5 June 2005  
 
914 Rear Caliper Rebuild
Model : Porsche, 914 - Series Category : Brakes
... you may drill into the end of the pivot (ask me how I know.) Knock the bit between the holes out and this will allow you to get a needle nose pliers in there to pry the entire plug out. After getting the plug out, small screwdrivers will allow you to get the retaining clip out. The arm is now ready to come out. Pull the arm out of the sleeve carefully. There is a dust boot right under the arm. ... (more)
Posted : 5 June 2005  
 
914 Transmission Selector Rod Seal Replacement
Model : Porsche, 914 - Series Category : Driveterrain - Transmission
... a machine shop that can do it for you. This roll pin can be seen in Figure 4. The best method of pressing out the roll pin involves using a vise and an old screw and nut. Place the screw against the roll pin, and place the nut on the opposite side. Place the entire assembly in a vise, and crank down, as shown in Figure 5. Complete the entire process by gradually increasing the length of the ... (more)
Posted : 5 June 2005  
 
914 Shifting Improvements
Model : Porsche, 914 - Series Category : Driveterrain
... grips helped to compress the bushing before I installed it into the firewall. After the new bushing is installed, you then need to replace the front shifter bar. To insert the bar back through the firewall, you need to access the bar through the small access port located under the center cushion. Removing the small metal plate allows you to get a grip on the rod and guide it into the ... (more)
Posted : 5 June 2005  
 
914 Oil Cooler Seals Replacement Tips
Model : Porsche, 914 - Series Category : Engine
... drive ratchet, with an odd assortment of sockets, etc to get just the right amount of extension to reach the nut, but not too much that you cannot fit it into the access space. I tried a lot of different combinations before finding one that worked.Now don’t forget that there are two 13mm bolts which attach a bracket from the far passenger side of the oil cooler to something solid like ... (more)
Posted : 5 June 2005  
 
914 Valve Cover Modification
Model : Porsche, 914 - Series Category : Engine
... the engine to remove them. This may be due to the suspension reinforcements that reduce the side clearance of the engine. Finally is the possibility of modifying the stock valve covers to add a metal strip around the inside of the gasket to hold it in place. This is the solution I finally settled on after having the sealant start leaking at a race recently. MODIFICATION STEPS: 1. Jack up the ... (more)
Posted : 5 June 2005  
 
Timing Porsche 914s with Carbs
Model : Porsche, 914 - Series Category : Fuel System
... all RPMs and speeds. The vacuum advance on the distributor lets up a bit, providing some retard, when the car is under load, like when punching it pass lesser cars, thus preventing ping (predetonation) and providing a smooth acceleration. If you don’t have an “advance” timing light, which allows one to dial in an advance and time to the TDC mark (or any other point for that ... (more)
Posted : 5 June 2005  
 
914 Timing and Dwell, Adjustment
Model : Porsche, 914 - Series Category : Engine
... upon where you set the timing. Note that for 1.8L engines, the timing is 7.5 BTDC (Before Top Dead Center) at 800-900 RPM. Also make sure that you have the vacuum hoses to the distributor disconnected and plugged, as the vacuum advance/retard will adversely affect your timing readings. For the 1.7L and 2.0L engines, the process is a little trickier. You need to pull on the accelerator ... (more)
Posted : 5 June 2005  
 
Rendezvous with a Dropped Valve Seat
Model : Porsche, 914 - Series Category : Engine
... the top of the case. Figure 3: The crank is pretty banged up, but intact. The Type IV motors have cranks that are pretty much bullet-proof. You really have to mess up big to crack or break a crank. Figure 4: Here you can see the inside wall of the case, and another angle of the crank. There's not even a serial number left. Figure 5: Fall out from the carnage. Check out the top of the case on ... (more)
Posted : 5 June 2005  
 
Fixing 914 Oil Pump Leaks
Model : Porsche, 914 - Series Category : Engine
... out of the case. The load on the threads is highest near the surface, and decreases as you go deeper into the stud hole. Under this load, the aluminum at the surface of the case may yield locally, raising a mound around the stud. Overtorquing the nuts on the studs (like, attempting to fix a leak!) increases the probability of raising a ring. It can also happen with time due to creep (slow ... (more)
Posted : 5 June 2005  
 
914 Engine Removal Made Easy
Model : Porsche, 914 - Series Category : Engine
... Don't use too much force, or you could damage the mating surfaces or the joints themselves. Once you have them disconnected, as shown in Figure 7, make sure you place a bag over the ends of the axles, and the flanges on the transmission. This is to protect both the joint from dirt and you from grease. If you skip this step, you will regret it later when you have CV joint grease in your ... (more)
Posted : 5 June 2005  
 
Replacing and Adjusting the 914 Clutch
Model : Porsche, 914 - Series Category : Driveterrain
... floor jack, pull the transmission and the jack rearward away from the engine, as shown in Figure 23. The transmission should require a little bit of coaxing to be separated from the engine case. Be careful not to accidentally let the transmission hang on the center driveshaft. This will most likely damage the transmission. Once the transmission is clear and the driveshaft is out of the ... (more)
Posted : 5 June 2005  
 
914 Valve Adjustment
Model : Porsche, 914 - Series Category : Engine
... in the valves for cylinder #1. Check this by seeing if the rockers will move slightly when rotated. At this point, it is time to adjust cylinder #1. Looking at Figure 16, determine which cylinder is #1. You may also look at the sheet metal in the engine compartment, which is marked with each piston number. This is shown in Figure 17 Figure 18 shows both the exhaust and intake valves for ... (more)
Posted : 5 June 2005  
 
Wiper Arm Reversal
Model : Porsche, 911 - Series Category : Misc
... reverse the 914s wiper location.After listening to the pros and cons of reversing the wipers I decided to do mine only because I like the way they look and the clear view I have of the road. The following is a short pictorial of this project.[Click on Image to Enlarge]BeforeAfterDrivers ViewPull back the trunk carpet and remove the 4 bolts that secure the panel in front of the instruments.Remove ... (more)
Posted : 5 June 2005  
 
911 Cup Holder Installation
Model : Porsche, 911 - Series Category : Interior
... than the gee-whiz gadget in your friend’s new Mercedes. It is machined from heavy aluminum alloy stock, and then black anodized. The brackets are also heavy-duty, and it has a spring-loaded ball detent to hold it open or closed. It looks like it belongs in an F-16 jet fighter (Figure 1). Best of all, you don’t have to drill any holes to mount it. To begin installation, measure 2 ... (more)
Posted : 5 June 2005  
 
911 Hood Strut Replacement
Model : Porsche, 911 - Series Category : Misc
... and stronger. The next thing to do is get some special tools together (Figure 3). I got the huge hemostat at Harbor Freight. It and the small one are very handy for working in tight places. Another item in the picture is dental floss, which is used to tie onto small parts, so that if you drop them into a crack, they can be retrieved. There are a lot of places in the boot for dropped parts to ... (more)
Posted : 5 June 2005  
 
911 Washer Pump System Troubleshooting
Model : Porsche, 911 - Series Category : Misc
... it break free and run (it won’t hurt the motor). When you reinstall the motor, be sure to connect the brown wire to the motor negative terminal (brown is always used for ground in Porsche). If the motor still won’t run, you need a new pump. This pump is used for the windshield and headlight washers on the 1978-1983 911SC. The headlight washer has a separate relay, hidden in the ... (more)
Posted : 5 June 2005  
 
911 Sunroof Repair
Model : Porsche, 911 - Series Category : Interior - Sunroof
... Figure 12: 3M Super Weatherstrip 80001Once you have the roof removed, it should be apparent how the track assembly works. The cable is attached to a guide that runs inside the aluminum channel. The motor pushes this guide forwards and backwards to open and close the sunroof. At this point, it’s advisable to completely remove all of the aluminum channels from the top of the sunroof and clean ... (more)
Posted : 5 June 2005  
 
Greg's Dark Blue 911 - Hacks Installation of DAS Rollbar
Model : Porsche, 911 - Series Category : Misc
... have the latch catch just behind the bolts and just above the lip. So far it seems to be the best way of doing it as it doesn't require any grinding! Click on thumbnail to view full-size image View of the bar and the driver seat touching from the top. Another view more from the side. Here you can see the contact. Slightly different angle. Here is a view from behind with the seat back tilted ... (more)
Posted : 5 June 2005  
 
911 Racing Harness Installation
Model : Porsche, 911 - Series Category : Misc
... the turns. I have a similar harness already installed in my Boxster. I've always wanted a Hotlap system, and now that I have a harness bar, I have someplace to mount it! Click on thumbnail to view full-size image The Brey-Krause harness bar went in pretty easily. The Sabelt shoulder belts simply wrap around the bar. See the warning at the top of this page. The Hotlap receiver mounts ... (more)
Posted : 5 June 2005  
 
Recarro Racing Seats Installation
Model : Porsche, 911 - Series Category : Misc
... one and I'm waiting for a decent day to install it. it now. Before beginning this hack yourself, you will need the following items: Recaro SRD Seat Recaro Seat Rails 6mm Allen Wrench 5mm Allen Wrench One tip I picked up from another shopper at Northstar Motorsports is to get a Porsche emblem patch, stick it to a sheet of Velcro hooks, then trim off the excess. I learned that the material ... (more)
Posted : 5 June 2005  
 
Hotlap Under-Dash Installation
Model : Porsche Category : Misc
... would attach it to the Boxster center console. I experimented with a variation of his bracket and after one unsatisfactory bracket, I came up with this that seems to be functional and rugged enough to last quite some time. The first bracket I made held up fine on the race track, even though it needed a zip tie to hold it in place, but it broke when I accidentally hit it with my knee while ... (more)
Posted : 5 June 2005  
 
Bleeding Porsche Brakes
Model : Porsche, 914 - Series Category : Brakes
... fluid stops coming out of the bleeder valve, close the valve, and then tell your family member to let their foot off of the pedal. Do not let them take their foot off until you have completely closed the valve. Repeat this motion for each valve at least three times. Repeat this entire procedure for all the valves in the same order as described previously. Then, let the car sit for about 10 ... (more)
Posted : 5 June 2005  
 
Upgrading to a 19mm Master Cylinder
Model : Porsche, 911 - Series Category : Brakes
... studs that stick out of the chassis are directly attached to the pedal cluster inside the cockpit. After the master cylinder is removed, the car should look like Figure 3. Installation is a bit more difficult than removal. The tough part is getting the reservoir fittings to properly seat into the new master cylinder. The new master cylinder should have new rubber boots that surround and ... (more)
Posted : 5 June 2005  
 
911 Caliper Rebuild
Model : Porsche, 911 - Series Category : Brakes
... the brake line, and use the brake system itself to force the pistons out. This is an almost fool-proof method, and a good reason for doing one caliper at a time. SAFETY NOTE: Keep your fingers out of the caliper at all times when you are using air pressure—it builds up enormous force, and can cause serious injury. The next step is to remove the old rubber piston seal from each caliper ... (more)
Posted : 5 June 2005  
 
911 Brake Pad Replacement
Model : Porsche, 911 - Series Category : Brakes
... rotors. If they have severe ridges, or if they are worn below the minimum thickness, they will need to be resurfaced or replaced. The same is true if they are warped or have excessive runout (a symptom of warpage or runout is steering wheel shimmy when you apply the brakes). (Figure 8) 7. Inspect the calipers. If they are leaking fluid, or if the rubber dust boot is damaged, they will need to be ... (more)
Posted : 5 June 2005  
 
911 Master Cylinder
Model : Porsche, 911 - Series Category : Brakes
... 10mm cap screws, two on the top and two on the bottom. (Figure 3) There is a flat washer and a lock washer on each screw. Be careful not to drop anything in this part of the boot, because it will probably fall into an irretrievable place. If your car has cruise control, remove the rectangular cruise control "brain" by unplugging the cable from the bottom. Then remove the brain itself ... (more)
Posted : 5 June 2005  
 
Brake Cooling Kit Installation
Model : Porsche Category : Brakes
... kit that bolts up to the brakes. Be sure to order the hub blocking plate also. To start, safely jack the car up and use jack stands. Remove the front tires so that you can see the brakes (see figure one). Next remove the two bolts that secure the calipers to the strut. Also, remove the spring clip to add flex in the lines. Separate the caliper from the strut and hold it up with tie straps. ... (more)
Posted : 5 June 2005  
 
RED Calipers
Model : Porsche Category : Misc
... Article: Pelican Guest Technical ArticlePermission to publish this article is provided generously by Robin Sun at www.p-car.com Be sure to visit his site for loads of 993 info!RED Calipers Something like is a typical Ricer Boyz behavior. But at least I spent the time and money and had this done the right way, and it turned out great. Took the original black calipers off and shipped them to ... (more)
Posted : 3 June 2005  
 
Sound Padding & Carpet Installation
Model : Porsche, 914 - Series Category : Interior
... carpet and trim, you need to work in tight areas where there is not too much ventilation. Using the respirator now may limit your chance of getting cancer later on. For me, it seems like a no-brainer. Once you buy the mask and have it around to use, you will be surprised at how much you will use it. The one I used was a Survivair #8621, and I was surprised when I opened the bag to see that ... (more)
Posted : 3 June 2005  
 
964 Rear Wing Installation
Model : Porsche, 911 - Series Category : Exterior
... of finish you want on your car after all this work. My primed (for the second time) wing was now ready for a final fit check before going to the painter. Everything lined up perfect and I was off to the shop. The wing I chose consisted of two parts – the base part with the spoiler and the bridge wing portion. When I got them back from Arrow Glen Body Shop in Ontario, the pieces were a ... (more)
Posted : 3 June 2005  
 
911 Suspension Spotting Guide
Model : Porsche, 911 - Series Category : Suspension
... by their red/orange color. Most Koni shock inserts were originally hydraulic, capable of being adjusted firmer or softer by removing the shock and manually adjusting the setting. Newer Koni replacement inserts are gas shocks with adjustment made by turning a knob at the top of the shock (taking only a few seconds to change the firmness). Koni struts can only use a Koni shock insert. Bilstein ... (more)
Posted : 3 June 2005  
 
Installing a 914/911 Front Sway Bar
Model : Porsche, 914 - Series Category : Suspension - Sway Bars
... refer to the Pelican article, Replacing the 914Gas Lines. You can also check out Brian Kumamoto's article on Gas Tank Removal and Reconditioning. That article contains all the tip and tricks for removing your gas tank without creating a Superfund cleanup site. Once the gas tank is removed, you should have easy access to the bulkhead area where the sway bar mounts are to be installed. It may ... (more)
Posted : 3 June 2005  
 
Steering Column Bushing Replacement
Model : Porsche, 911 - Series Category : Interior - Steering Wheel
... column, a lengthy procedure. Fortunately, there is an easy, inexpensive, quick fix.The part that actually fails is a white plastic bushing inside the bearing (Figure 1). It begins to crack and disintegrate, and causes noise and unwanted play. The repair part is a slotted metal bushing that is simply driven into the top of the steering column (Figure 2). The metal bushing displaces the plastic ... (more)
Posted : 3 June 2005  
 
911 Steering Wheel Spoke Repair
Model : Porsche, 911 - Series Category : Interior - Steering Wheel
... steering wheel:a. Remove the horn pad. The horn pad is attached to steering wheel by three pressure snaps at each spoke. Remove the pad by pulling away from the steering wheel. The electrical connection for the horn will disconnect when the horn pad comes off.b. The steering wheel fits over the steering column shaft and is held in place with a 27mm bolt. Apply WD-40 to bolt, wait ... (more)
Posted : 3 June 2005  
 
911/914 Strut Removal
Model : Porsche, 911 - Series Category : Suspension
... on the hard line nut and counter hold the brake hose with a suitably sized wrench. Remove the retaining clip and set it aside. At this time let the brake fluid drain into a suitable container. (Figure 5, Figure 6 and Figure 7) 5. Place another (or the same one) pan under the caliper banjo fitting. Remove the banjo bolt and sealing washers from the caliper(you will need to get new washers so ... (more)
Posted : 3 June 2005  
 
911 Rear Suspension Bushing Replacement
Model : Porsche, 911 - Series Category : Suspension
... One is where I marked the position of the plate before I dissasemble. This was used as a point of reference when putting it back together. Scribbing that mark is VERY important, it would be hard to do this without that reference point. The second mark was scribbed after installation. The difference in angle will result in the change in ride HEIGHT. I carefully compared the angle difference on ... (more)
Posted : 3 June 2005  
 
911 Monoball Installation
Model : Porsche, 911 - Series Category : Suspension
... slides into place to the stop.3. Next, slide the snap-ring down into the groove in the cartridge, chamfer facing away from the monoball (i.e. flat surface of snap-ring against the monoball).4. Now, heat the bearing area of the trailing arm to expand it slightly, the directions say not to exceed 180 degrees. Just get it warm with a few seconds exposure to the propane heat. The cartridge will ... (more)
Posted : 3 June 2005  
 
Replacing Wheel Bearings on a 1986 930
Model : Porsche, 911 - Series Category : Suspension
... the brake shoes are out it is a simple linkage to remove and replace.Clean everything up as best you can using your favorite grease removal materials, both outside and inside of housing.Remove outer race of outer bearing (wheel side). Porsche says take off the swing arm and use a special tool in a bench press, not an option for most of us. With lots of care, a long drift a big hammer and ... (more)
Posted : 3 June 2005  
 
911 Front Suspension Bushing Replacement
Model : Porsche, 911 - Series Category : Suspension - Bushings
... bushings are a soft compound rubber and flow as a result of weight resting on them. I found my bushings had not worn that much in 240k miles, but had flowed quite a bit. Here is a shot of the bushing from the rear of the control arm: You can see the difference in thickness on the two sides. The thin side is where the weight rested. Here is a shot of the front bushing: The front did not flow, ... (more)
Posted : 3 June 2005  
 
911 Fuel Injector Replacement
Model : Porsche, 911 - Series Category : Fuel System
... the fuel distributor to the intake manifold runners. WARNINGThis procedure should be done in a well-ventilated area, away from any ignition sources. Wait until the engine is dead cold, and remove the two air hoses on the drivers side of the engine (one plastic one and one paper/wire one). Squirt a little WD-40 around each injector where it is seated in the intake runner. This will free it up ... (more)
Posted : 3 June 2005  
 
911 Carrera Engine Starting Troubleshooting
Model : Porsche, 911 - Series Category : Engine
... pump). If it runs, it probably indicates some kind of DME problem (the DME is not sending power to the fuel pump). If still doesn’t run, it’s probably not a DME problem. Thanks to Jim Bauman for sharing this tip. 5. If it is a DME problem, replace the DME relay, which sends power to the fuel pump. This is another one of those parts that is known to be flaky. The relay is under the ... (more)
Posted : 3 June 2005  
 
Cylinder Head Temperature Sensor - Upgrade
Model : Porsche, 911 - Series Category : Fuel System
... the sensor (the connector on the right which is fixed to the bracket) and the negative probe on a known good ground. If the sensor is working properly, it should read in the 1-2k ohms range. If it reads zero or infinity the sensor is probably bad. Interestingly, I can’t seem to get a proper resistance reading from the new sensor, but it definitely works. Okay, here’s the procedure for ... (more)
Posted : 3 June 2005  
 
CIS Pop Off Valve Installation
Model : Porsche, 911 - Series Category : Fuel System
... saw, one with a long pilot drill, or one that is adjustable if preferable. If the pilot drill is too short, the hole saw teeth will contact the ribs in the air box floor first making drilling more difficult. To begin installation, remove the air filter. Carefully position the template in the bottom of the airbox, and drill the hole. (Figure 1) Note that the arrow on the template should be ... (more)
Posted : 3 June 2005  
 
911 Fuel Fittings Replacement
Model : Porsche, 911 - Series Category : Fuel System
... the fuel pump in my 1983 911SC in an attempt to repair a tiny but bothersome fuel leak. When the leak persisted after the fuel pump was replaced and all fittings tightened (and retightened), I discovered the true source of the leak. It was a fitting in the fuel pump outlet line that was leaking. When the fitting was removed for repair, it was apparent that the end ferrule connecting the ... (more)
Posted : 3 June 2005  
 
911 Fuel Pump Replacement
Model : Porsche, 911 - Series Category : Fuel System
... where the fuel system will be opened is to position the car away from any possible sources of ignition, such as a gas water heater, because you are likely to spill some fuel. Next, place the front of the car up on jack stands. (Figure 2) You need some room to work under the car, so the car should be near the maximum HEIGHT of the jack stands. I usually place them as shown (Figure 3), with a ... (more)
Posted : 3 June 2005  
 
C2/C4 Airbox Modification / Upgrade
Model : Porsche, 911 - Series Category : Fuel System
... mod to perform on the C2/4 engine. The stock airbox does not allow enough airflow to get into the intake system. Drilling a set of holes in the airbox housing will open it up and allow more air to breathe into the engine. First step is to remove the airbox cover located on the right side of the engine compartment. When you do this you’ll see the air inlet to theengine. These are more ... (more)
Posted : 3 June 2005  
 
911 Motronic Chip Upgrade
Model : Porsche, 911 - Series Category : Fuel System
... I guess I'll never know. Before beginning this hack yourself, you will need the following items: Autothority Performance E-Proms part# POR.01.911.300 10mm socket, socket wrench, and a variety of extenders Flat blade screwdriver Sharp knife Needle-nose pliers, for picking up things that fall in annoying places. A tank full of 92 octane gasoline. Some people have suggested removing the ... (more)
Posted : 3 June 2005  
 
Installing H4 Headlamps
Model : Porsche, 914 - Series Category : Lights
... fender. Now is a good time to replace it if it is worn or broken. Next remove the three small screws holding the chrome headlight retainer (Figure 5). These three screws tend to strip easily, so you may want to spray them with WD-40 first, and make sure you have a good grip on them before trying to turn the screw. Once these three screws come out you can remove the headlight from the assembly ... (more)
Posted : 3 June 2005  
 
Porsche Dashboard Gauge Repair and Refurbishment
Model : Porsche Category : Interior
... to put the unit back together without messing up the specific number that you want. Push the odometer driveshaft back into the housing and through the pot metal gear. Depending upon how you decided to deform the wheel, this may take some force. Make sure that all your numbers are lined up before pushing the shaft back into the pot metal gear. Check it by looking carefully at the face on the ... (more)
Posted : 3 June 2005  
 
Starter System Troubleshooting
Model : Porsche, 914 - Series Category : Electrical - Starter
... tube, or a good tape wrap. It would be best to cover the splice with some split tubing from your FLAPS to protect against chaffing, and to ensure that the tape does not unwind. Last, but not least, check out the starter itself. This item has two distinct components: the solenoid, and the motor itself. First, check the voltage on the starter solenoid input terminal (on the bolt itself) (this ... (more)
Posted : 3 June 2005  
 
911 Alternator & Voltage Regulator Removal/Replacement
Model : Porsche, 911 - Series Category : Electrical - Alternator
... positions. From your viewing vantage point (from fan end of alternator), with the regulator on "top", the red wire was at the bottom, blue to left, brown ( 2 wires) to right. Note that the red wire uses a 10mm head bolt, brown uses 8mm, and blue uses 7mm. I guess this is supposed to help us, if we don’t remember the wire locations (!). 10.) Now the entire cast fan housing , ... (more)
Posted : 3 June 2005  
 
911 Alternator and Fan Replacement & Upgrade
Model : Porsche, 911 - Series Category : Electrical - Alternator
... away from the fan shroud. The fan/alternator assembly is shown in Figure 13. Now, you can separate the fan/alternator from it's outer circular housing. Remove the screws that hold the alternator to the housing, and light tap on the studs with a hammer. The housing should begin to separate from the fan & alternator. A few more tugs, and the two should come apart, as shown in Figure 14. The ... (more)
Posted : 3 June 2005  
 
Adding a 3rd Brake Light
Model : Porsche, 911 - Series Category : Lights
... jack and run wire underneath to avoid snagging later. My car came with duct tape (factory installed ?) to keep the ground wires away from getting snagged by the jack. 3) Run a fish wire down the 3rd vent opening. The wire needs to be pulled out the 3rd vent hole and then worked over to the first hole. 4) Leaving at least 2 inches of spare wire, crimp quick connect lug at top of hatch. 5) ... (more)
Posted : 3 June 2005  
 
Brighter Instrument Lights for your Porsche
Model : Porsche, 911 - Series Category : Interior
... is to replace these old bulbs with new ones, a procedure that can be done in just a few minutes’ time. For a 911SC, you will need a total of eight 12 volt, 2 watt bulbs—“indicator lamps”, as they are termed by Osram, one of the manufacturers. To begin, pull the instrument from the dash. In the early cars, before the early 70s, this takes a bit more work, because the ... (more)
Posted : 3 June 2005  
 
Solving Electrical Problems
Model : Porsche, 912 - Series Category : Electrical
... -disconnect the ignition coil's red wire and fit a 15 ohm 5watt resistor between the red wire and chassis. These resistors are cheap and availeble at any electronic part shop. Solder a wire at each side of the resistor with a crocodile connector to ease installation. -take a voltmeter. Make one 5 meter long test wire. Fit this wire between the + of the 12V power supply and the + input of your ... (more)
Posted : 3 June 2005  
 
964 White Gauge Faces
Model : Porsche Category : Interior
... Quite a dramatic change. Especially against the white exterior of the car.To remove the first gauge, in this case the gas gauge, I used a screwdriver that I had covered the tip with clear tape so it would not scratch the gauge during the removal. Using the screwdriver and a small piece of foam to protect the adjacent gauge and upholstery, I loosened the gauge to start removing it from the ... (more)
Posted : 3 June 2005  
 
Gauge Face Replacement
Model : Porsche, 911 - Series Category : Interior
... out until it is even with the edge of the gauge housing. Figure 15 Now pry (carefully!) the bezel away from the edge of the housing. You will have to go around the gauge to get it to come off. Figure 16 The bezel will now come off of the gauge. There are 3 pieces, the outer bezel, inner bezel and the glass. This is a good time to clean the glass on your gauge. Figure 17 After you clean the glass ... (more)
Posted : 3 June 2005  
 
Installing a 3rd Brake Light in the 911
Model : Porsche, 911 - Series Category : Lights
... you don't nick it with the drill when you make the mounting holes. Next you will need to take the gasket and mark the position on the hood (Fig 1) light will be installed at. Then you will have to drill 3 holes in the hood. The outer holes should be " in diameter. The middle hole should be just large enough to fit the wires through (Fig 2). Don't worry about the plug in the middle of the ... (more)
Posted : 3 June 2005  
 
Installing a Rotary Air Conditioning Compressor
Model : Porsche, 911 - Series Category : Interior - Heating and Air Conditioning
... the fitting on the condenser with another wrench-this is a fragile and expensive part. (Figure 3) Tip the compressor up on end to gain access to the suction hose, and unfasten it from the compressor. This hose will be reused, so there is no need to detach its other end. Remove the old compressor, and check that the bolts holding the compressor mount to the engine are tight. Remove ... (more)
Posted : 3 June 2005  
 
Heater Flapper Box Replacement: Removal
Model : Porsche, 911 - Series Category : Interior - Heating and Air Conditioning
... Box Replacement Order Online or Call: 888-280-7799 Search our site: View Cart | CheckOut | Order Status | Help BMW Section California SpeedFestival - PCA Porsche 911Online CatalogTech Articles993/996 TechTech Q&ATech EmailBuyer's GuideParts DiagramsElec Diagrams911 BBSPhoto Gallery911 Classifiedsmore 911 stuffPorsche 914Online CatalogTech ArticlesTech Q&ATech Email914-6 ConvBuyer's GuideTech ... (more)
Posted : 3 June 2005  
 
911 Cooling Boost
Model : Porsche, 911 - Series Category : Engine - Cooling System
... When the engine oil temperature is high, and the car is stopped, the control unit switches on the heater blower to get some extra cooling by blowing air through the heat exchangers. Because the heater valves are open, this hot air is simply vented into the atmosphere. If you have a 911 with manual heater controls and the heater blower in the engine bay, you can make an easy modification to ... (more)
Posted : 3 June 2005  
 
Exhaust System Upgrades
Model : Porsche, 911 - Series Category : Exhaust
... tailpipe slips snugly onto the muffler outlet, and is held in place by a heavy stainless steel clamp. (Figure 4) This article describes the installation of the GHL muffler on Bob Tindel’s 1983 911SC. Your car may differ slightly. A day or so before you start this project, I recommend spraying all of the fasteners, including the ones that hold the front of the catalytic converter to the ... (more)
Posted : 3 June 2005  
 
C2/C4 Primary Muffler Bypass Pipe Installation
Model : Porsche Category : Interior - Heating and Air Conditioning
... that all of the sound deadening material could insulate the engine a little too well and certainly increase case temps if nothing else. I did not notice an increase in the engine noise after I finished this project but then the exhaust is louder as well.With the pan removed you have access to everything. The primary muffler is the one across the back of the car under the rear valence.The ... (more)
Posted : 3 June 2005  
 
Early Heat Exchanger Retrofit
Model : Porsche, 911 - Series Category : Interior - Heating and Air Conditioning
... heat…trust me I tried. So heat each nut till bright red. I even turned off my work light, and heated the nuts, and would check by removing the torch for a second to see if the nut was indeed glowing. For some nuts it will be impossible but try to heat all around the nut perpendicular to the exhaust stud, heating just the nut. Once it is bright red, give it a good long squirt with water. ... (more)
Posted : 3 June 2005  
 
964 Rear Blower Motor Replacement
Model : Porsche Category : Interior - Heating and Air Conditioning
... leads to the blower and the resistor. You will also need to disconnect the hoses to the distributor and rear light vents then loosen the band clamps at the top and bottom of the tube that the resistor is mounted in. Wiggle the assemble to loosen the boot connection to the engine shroud and remove it from the engine. At this time you might want to ensure your resistor was replaced in the PO2 ... (more)
Posted : 3 June 2005  
 
1988 911 Nippondenso A/C Compressor Rebuild
Model : Porsche, 911 - Series Category : Interior - Heating and Air Conditioning
... local source for such things. I don’t. The pulley may be somewhat difficult to take off but you should not need anything like a gear puller. If you look inside the pulley’s shaft tube you can see the bearing that carries the pulley held in by a retaining spring. This may need to be replaced at some point. Mine did not require replacement. See Figure 4.5. The ground for the clutch ... (more)
Posted : 3 June 2005  
 
911 AC Refrigerant Recharge and Maintenance
Model : Porsche, 911 - Series Category : Interior - Heating and Air Conditioning
... The low pressure service port is usually identified by a blue cap. If it cannot be identified by the cap color, it can be identified by tracing the low pressure line that connects the evaporator to the compressor. 2) start the engine and set A/C dashboard controls to max cooling. 3) remove blue cap from service port. Connect the pressure gauge to the low pressure service port through the ... (more)
Posted : 3 June 2005  
 
Shifter Rod Seal Replacement
Model : Porsche, 911 - Series Category : Driveterrain
... have to use trial and error to figure it out later. If you are not happy with the location of your shifter rod, or the performance of your shift linkage, then you might want to adjust this when you reconnect it. Remove the shift coupler by loosening the pinch bolt, and sliding it off the linkage bar. When the coupler is disconnected from both the linkage and the transmission, you can slide it ... (more)
Posted : 3 June 2005  
 
Pedal Cluster Rebuild
Model : Porsche, 911 - Series Category : Driveterrain
... one. Give us a call if you need a replacement spring - Pelican Parts regularly stocks both of these. The majority of the cluster is held in by a roll pin that is inserted through the end of the clutch pedal. The hardest part of rebuilding the cluster is getting the old pin out. There are a few ways of doing this, and none of them work very well. As an alternative, you can take the cluster to ... (more)
Posted : 3 June 2005  
 
Repairing the Fuel Tank Sending Unit
Model : Porsche, 911 - Series Category : Fuel System
... if it’s in good enough condition to use again. Mine was.Disassembly: The sender is a long cylinder, about 300mm in length and 40mm in diameter with electrical connectors at the top and pin holes to allow the fuel to enter the unit at the bottom. It’s secured by a 4mm nut and locking washer at the bottom.9. With needle nose pliers, bend the small locking washer flat so you can access ... (more)
Posted : 3 June 2005  
 
911 Alternator and Fan Replacement & Upgrade
Model : Porsche, 911 - Series Category : Electrical - Alternator
... away from the fan shroud. The fan/alternator assembly is shown in Figure 13. Now, you can separate the fan/alternator from it's outer circular housing. Remove the screws that hold the alternator to the housing, and light tap on the studs with a hammer. The housing should begin to separate from the fan & alternator. A few more tugs, and the two should come apart, as shown in Figure 14. The ... (more)
Posted : 3 June 2005  
 
Installing the 911 Factory Short Shift Kit
Model : Porsche, 911 - Series Category : Driveterrain - Transmission
... from the shift tower. On the late-style tower, you unthread the allen bolt that forms the front longitudinal (fore-and-aft running) pivot, then press out the interference-fit piece for the rear pivot. I suspect an early tower would just have the interference-fit pieces on both ends. To press out the pivot, I slid a breaker bar through the pivot cage, placed its flat edge against the pivot, then ... (more)
Posted : 3 June 2005  
 
Factory Short Shift Kit Installation
Model : Porsche, 911 - Series Category : Driveterrain - Transmission
... four screws (Figure 2 and Figure 3). Next, remove the trim piece inside the console opening, by removing the two screws on the left outside of the console (Figure 4). Remove the knobs from the air conditioner temperature and fan controls, and remove the retaining nuts for these two units. Take out the two screws on each side of the console, and pull down the AC control panel. Push the two AC ... (more)
Posted : 3 June 2005  
 
Replacing 1st Gear on the 901 Transmission
Model : Porsche, 911 - Series Category : Driveterrain - Transmission
... filler plug with an old drain plug, which is magnetized. Hopefully, this would help reduce the metal particles floating in the gear oil. After the transmission is empty, then disconnect the speedometer cable that connects to the rear transmission cover. It also may be wise to disconnect the shift linkage, since the transmission may be dropping down a few inches. If you decide to keep the ... (more)
Posted : 3 June 2005  
 
911 Starter Installation
Model : Porsche, 911 - Series Category : Electrical - Starter
... Make sure that the car is held up securely, because you will be working underneath the car. The starter is located directly above the inboard CV joint of the right axle. (Figure 3) It may initially look difficult to access, but it is not. Pull off the two yellow wires from the spade connectors on the starter solenoid. Remove the nut from the main terminal on the solenoid, and remove the battery ... (more)
Posted : 3 June 2005  
 
911 Oil Cooler Scoop Installation
Model : Porsche, 911 - Series Category : Engine
... Carrera radiator type cooler. This scoop is made of heavy fiberglass, and the color and finish are an exact match to the black trim on a 911. Take a look at our on-line catalog for more details. To begin the installation, jack up the right front of the car and put a jack stand under it for safety. (Figure 1) Now reach inside the lower right front fender and locate the two 8mm nuts that retain ... (more)
Posted : 3 June 2005  
 
911 Engine Oil Cooler Replacement
Model : Porsche, 911 - Series Category : Engine
... oil. On early cars (up to SCs I think), the shroud included a separate "plastic" tunnels that was riveted to the fiberglass shroud. The tunnel included a wrap around end cap for the oil cooler. On later cars, while the shroud still included the tunnel, the end cap that fit over the cooler was not an integral part of the tunnel. If you have a later car or one that has been updated, ... (more)
Posted : 3 June 2005  
 
911 Spark Plug Replacement
Model : Porsche, 911 - Series Category : Electrical - Ignition
... the braided ground straps are routed around the wires. When assembling the wires to the cap, apply a thin coat of dielectic grease on the end of each wire, around the outside of each nipple on the distributor cap and coil, and inside the end of each spark plug connector. This will ensure good electrical contact, and help with disassembly in the future if it is necessary. Be sure to orient the ... (more)
Posted : 3 June 2005  
 
Installing an MSD Ignition System
Model : Porsche, 914 - Series Category : Electrical - Ignition
... 6 kit. Where to Mount It? This seems to be a subject of personal taste, but I will submit that having the shortest wires is a sound objective in selecting a mounting location for MSD unit. To this end, mounting on the firewall, under the rear window, above and to the right of the coil, near the battery, keeps all wires nice and short. As an added bonus, when you open the engine lid, people ... (more)
Posted : 3 June 2005  
 
Setting 911 Distributor Static Timing
Model : Porsche, 911 - Series Category : Electrical - Ignition
... plug #1 and put your hand over the hole, you’ll feel pressure when the crankshaft turns to the compression cycle for cylinder #1.Use a pointer as a flag. If you remove spark plug #1 and stick something (like a screwdriver or pencil) in the hole, it will push out when cylinder #1 reaches TDC. But be sure there is room for the screwdriver or pencil to move freely! Note: If you’re unsure ... (more)
Posted : 3 June 2005  
 
911 Oil Return Tube
Model : Porsche, 911 - Series Category : Misc
... Figure 6. Now, you need to remove the old tube. On some cars, you may need to remove the heat exchangers or headers to gain access to a particular oil return tube. Be careful when pulling the heat exchangers off of the heads as you don't want to accidentally remove the head studs. The best method for removing the oil return tube is to just take a pair of vise grips and crush the tube until ... (more)
Posted : 3 June 2005  
 
Oil Cooler Fan Wiring
Model : Porsche, 911 - Series Category : Engine - Cooling System
... of the car, in this case an SC. This fuse is a 25-amp, for the sunroof, rear wiper, and mirrors.) Use heavier gauge wire, such as 10 gauge. 3. Wire terminal 87 to the fan motor positive terminal, using 10 gauge wire. 4. Wire terminal 86 to the bottom of fuse 14, using 16 gauge wire (16 amp fuse, wiper/washer and cigarette lighter. 5. Wire terminal 85 to the thermostat, using 16 gauge wire (if ... (more)
Posted : 3 June 2005  
 
Porsche Oil Coolers, Form & Function
Model : Porsche, 911 - Series Category : Engine - Cooling System
... CatalogTech ArticlesTech Q&AParts DiagramsElec Diagrams356 BBSPhoto Gallery356 Classifiedsmore 356 stuff...PhotosPorsche EventsOwner's GalleryClassifiedsCars For SaleUsed Parts For SaleExtrasEvents CalendarChat RoomFree EmailFree Web PagesHome > Tech Articles > Porsche Oil Coolers - Form & FunctionGuest Technical Article: Porsche Oil Coolers, Form & Function Part II - Cooling ... (more)
Posted : 3 June 2005  
 
Mocal 44-Row Oil Cooler Installation for the 911
Model : Porsche, 911 - Series Category : Engine - Cooling System
... so that the mounting holes in the fan flanges are positioned over the centerline of the fan mounts and mark the positions of the holes on the fan mounts (Photo 5).Photo 5 – Aligning FanDrill a 7/32" hole in each fan mount and tap it with a " X 20 tap. Secure the fan to the frame with " X 20 X " bolts and lock washers (Photo 6).Photo 6 – Attaching FanStep 3 – ... (more)
Posted : 3 June 2005  
 
Remote Oil Cooler Installation
Model : Porsche, 911 - Series Category : Engine - Cooling System
... into the rocker cover and are not visible from the side. They are also protected from jacking plates.Jump to Page 2Got more questions? Join us in our Porsche Technical Forum Message Board, and ask a question to one of our many automotive experts Search our site: View Cart | CheckOut | Order Status | Help Recommend this page to a friend... [Home] [Customer Service] [Shopping Cart] [Project/Wish ... (more)
Posted : 3 June 2005  
 
911 Carrera Oil Cooler Upgrade
Model : Porsche, 911 - Series Category : Engine - Cooling System
... every curve and turn that the shield makes. The thermostat should be installed and wired at this point. The original factory thermostat clicked on the fan at about 240F – way too hot for some people’s tastes. There is an alternative thermostat switch that will start the fan running at a much cooler 210F. This switch is actually a compatible BMW part. Install this thermostat switch ... (more)
Posted : 3 June 2005  
 
911 Oil Leak Fixes
Model : Porsche, 911 - Series Category : Engine
... and also over on the side of the engine. When all the hose clamps that need to be loosened are, and the 2 support brackets holding up this network of tubing are undone, the tubes can be pulled off. But even with this, the breather cover still does not have the clearance to be lifted clear of its studs. So to solve this, I undid the intake manifold nuts on the 2 most flywheel side cylinders ... (more)
Posted : 3 June 2005  
 
Upgrading to 911 Turbo Valve Covers
Model : Porsche, 911 - Series Category : Engine
... on the nozzle. Don't spray any water inside the engine compartment, as there are many things in there that you just don't want to get wet. Instead, use some degreaser on a rag to wipe out the inside of your engine compartment. Please don't dump any degreaser on your driveway, as this pollutes the environment. If you suspect that your valve covers are leaking, then simply remove them off ... (more)
Posted : 3 June 2005  
 
911 Engine Tin Cooling Modification
Model : Porsche, 911 - Series Category : Engine - Cooling System
... a 1” wide strip out of the four middle cooling deflectors (see photo 1). This allows air to circulate more freely around the cylinders, making them run cooler and reducing the probability of pulling head studs. The strip you cut out runs along the outer edge of the deflectors. It starts at the top edge, and ends a small distance above the crease where the legs of the deflector spread ... (more)
Posted : 3 June 2005  
 
Fan Belt and Pulley Replacement
Model : Porsche, 911 - Series Category : Engine - Cooling System
... Seeing how most people don't have this tool, you can use a small screwdriver inserted in the holes of the pulley, to constrain the fan from moving. Do not use any tools on the actual fan blades. These blades often break off, and replacement fans can be expensive. While holding the pulley from turning, loosen the nut on the pulley shaft. This nut is a metric size 22mm, but in a pinch, a ... (more)
Posted : 3 June 2005  
 
Clutch Cable / Helper Spring Replacement & Adjustment
Model : Porsche, 911 - Series Category : Driveterrain
... When there is slack in the cable, the end should slide off of the hook, shown in Figure 5. Now pull out the cable from underneath the car. If you have properly removed the trunion pin from the other end of the cable, it should just slide out underneath the car. Installation of the new cable is relatively easy. Take the new cable, and guide the threaded end into the tube located on the firewall. ... (more)
Posted : 3 June 2005  
 
911 Timing Chain Replacement
Model : Porsche, 911 - Series Category : Engine
... been changed already. After opening the chain I used the master link from the new chain and connected it to the old one. Next step was to make a tool to slip in between the chain and the top side of the crank gear (I cut a piece of plastic 1-1/4" by 10" flat) My homemade tool looked like a ruler but was thinner and more flexible. I worked the plastic tool between the top of the crank ... (more)
Posted : 3 June 2005  
 
911 Carrera Chain Tensioner Installation
Model : Porsche, 911 - Series Category : Engine
... you have a timing light handy, as you will need to reset the timing on the engine when you replace the distributor.Once you have access to the rear of the engine, remove the left and right chain housing covers. You should see the old-style chain tensioners as shown in Figure 4. If your chain ramps are looking worn, now is a good time to replace them. The upper chain ramp on the right side is ... (more)
Posted : 3 June 2005  
 
911 Clutch Replacement
Model : Porsche, 911 - Series Category : Driveterrain
... Figure 21 shows the pilot bearing installed. You are now ready to install your flywheel on to the transmission. You should always use a new or resurfaced flywheel in your clutch job. Your clutch performance can be severely affected if you do not. Figure 22 (901) and Figure 23 (915) show resurfaced flywheels. On the 915 transmission, the starter ring is separate from the flywheel. When you ... (more)
Posted : 3 June 2005  
 
911 Engine Removal Made Easy
Model : Porsche, 911 - Series Category : Engine
... out when the oil cools down. Make sure that you use a paper towel to clean off the plug well, as shown in Figure 5. These plugs are often magnetic, and trap bits of metal that wear off of the engine. Clean it very well using a paper, not cloth, towel. Any stray paper fibers will dissolve in the engine oil later on; the cloth fibers have a tendency to clog tiny oil passages. Tighten the drain ... (more)
Posted : 3 June 2005  
 
911 Valve Adjustment Made Easy
Model : Porsche, 911 - Series Category : Engine
... may need to disconnect and slide the compressor out of the way. This is an easy and common procedure. Be sure to wrap the compressor in a blanket to avoid having it damage other items located in the engine compartment. On some cars, there may be some plastic ducting located on the left side, near the blower motor. This may have to be removed as well. Basically, you need to get access to remove ... (more)
Posted : 3 June 2005  
 
Extracting Power from CIS 911s
Model : Porsche, 911 - Series Category : Engine
... of the more radical (high-lift, long-duration) camshaft grinds, which is the main reason it must be discarded to build extremely powerful street and racing motors. Fuel flow in the CIS system is controlled by the rising and falling of a round sensor plate inside a conical housing, or venturi. The more the throttle butterfly valve is opened, the more air gets sucked into the airbox intake and ... (more)
Posted : 3 June 2005  
 
911 Motor Rebuild Overview
Model : Porsche, 911 - Series Category : Engine
... me lower the half into place, all the while making sure that the timing chain and connecting rods weren’t hung or fallen out of place. I used a mallet to gently tap the case halves together and immediately started hand tightening the multitude of 13mm. Perimeter (crankcase flange) loc-nuts. As my friend was busy fumbling with the loc-nuts, I was busy installing the crankcase ... (more)
Posted : 3 June 2005  
 
REVIEW: Bruce Anderson & Jerry Woods' Engine Overhaul Class
Model : Porsche, 911 - Series Category : Engine
... at the engine dyno. Jerry has a specially designed engine dynamometer room that he uses for each and every 911 engine that comes out of the shop. The room is soundproof, but you can only do so much - we heard him testing an experimental 911 engine from the classroom located next door. The dyno process was truly interesting to watch and learn, as Jerry used a laptop computer to tune and adjust ... (more)
Posted : 3 June 2005  
 
Time to Rebuild?
Model : Porsche, 911 - Series Category : Engine
... of two quarts per 1000 miles is certainly cause for concern. There are two places that the oil can be lost, either past the piston rings, or the valve guides. If the car is excessively smoking, then there is significant oil being burned in the combustion chamber. Air-cooled engines expand significantly when they are run. It’s not uncommon for the entire engine to expand more than ... (more)
Posted : 3 June 2005  
 
993 Rear Fog Lights
Model : Porsche, 993 - Series Category : Lights - Fog Lights
... weather condition may cause road rage or may even result you in a traffic ticket. This DIY originated from Gert in Belgium, Gert did this DIY on his 993 and kindly passed his knowledgeable experience and information to me to make this DIY possible for U.S. 993 owners who want to add this option to their 993. 993 rear fog lights are standard equipment in Europe but was not installed in the ... (more)
Posted : 3 June 2005  
 
Rekeying Locks
Model : Porsche Category : Misc
... and error. With your fingers or a pair of needle-nose pliers, remove one of the tumbler pins, as shown in Figure 6. Becareful not to lose the small tumbler springs that push the pins outward. These are very small and have a tendency to fall out when you least expect it. In order to perform the lock rekeying properly, you need a set of replacement tumbler pins. These pins come in four different ... (more)
Posted : 2 June 2005  
 
Porsche Air Conditioning Frequently Asked Questions
Model : Porsche Category : Interior - Heating and Air Conditioning
... firmly to the case and connected to the Crankshaft by a belt.The Evaporator is inside the passenger compartment so that air can be picked up by the fan and sent across the cooling coils and back out through the vents.The condenser that is normally placed in front of the radiator in a 'real' car must be placed in the air stream or where there will be a steady high volume of cold air since ... (more)
Posted : 2 June 2005  
 
Emergency Breakdown Kit, Replacing the 911 Fan Belt, Stopping Break Squeaks
Model : Porsche, 911 - Series Category : Misc
... nut loosens the dome washer behind the nut will loosen also. As the nut, dome washer, and the pulley are removed you will see some shims behind the dome washer. You will also see more shims on the other side of the fan pulley. There are usually six total. These six shims are necessary to set the proper tension on the new belt and correctly space the pulley. Start with three on each side of the ... (more)
Posted : 2 June 2005  
 
Spark Plugs, Trouble with CATs, Installing Late Gauges in Early 911s,
Model : Porsche, 911 - Series Category : Misc
... an Early 911 The early 911 and 356’s secured their instruments to the dash panel with 'U’ brackets and hand tightened screw nuts. This was an excellent method until the area behind the dash was all filled up with ducts and other components. The factory started installing instruments from the front in 1969 as access was impossible without removing the whole ventilation system. You ... (more)
Posted : 2 June 2005  
 
Hot Rodding Your Floor Jack
Model : Porsche Category : Misc
... I can't recall anyone looking at my floor jack and saying " Wow, bitchen jack Dood !" Well, we're going to change that.This is where it all started. This jack needs a little cleaning up. So after hosing it down I started taking it apart. No brain surgery here ! Pretty simple stuffI had to come up with a color scheme that would give it some life - so when in doubt go with Red. ... (more)
Posted : 2 June 2005  
 
Electrical System Upgrades
Model : Porsche, 911 - Series Category : Electrical
... and time. Severe fatigue results in smoke, melting wire insulation, and fire. 930 Turbos with two fuel pumps, and all the warm-up gadgets on the engine, simply over tax that system. Most of the 930’s have had at least one fuse block replaced. I have removed some of the original battery feed cables that went directly to the fuse block and I have them run directly from the battery to each of ... (more)
Posted : 2 June 2005  
 
VDO Dashboard Gauge Repair and Refurbishment
Model : Porsche Category : Interior
... driveshaft back into the housing and through the pot metal gear. Depending upon how you decided to deform the wheel, this may take some force. Make sure that all your numbers are lined up before pushing the shaft back into the pot metal gear. Check it by looking carefully at the face on the mechanism, as shown in Figure 18. It is possible to have numbers that are half-turned and not even ... (more)
Posted : 1 June 2005  
 
Gauge Face Replacement
Model : Porsche, 911 - Series Category : Interior
... the bezel away from the edge of the housing. You will have to go around the gauge to get it to come off. Figure 16 The bezel will now come off of the gauge. There are 3 pieces, the outer bezel, inner bezel and the glass. This is a good time to clean the glass on your gauge. Figure 17 After you clean the glass with a lint free cloth, put it to the side along with the other parts while you ... (more)
Posted : 1 June 2005  
 
Hacks Installation of 930S Steering Wheel
Model : Porsche, 911 - Series Category : Interior - Steering Wheel
... was only one but that they sell a spacer that will give me approximately 1/2" (actually 1.5 centimetres) of additional clearance. If you decide to go this route the AJ USA part number is AJR 347 099 and costs around $28. If you do use this adapter, which did the trick for me, make sure you install the hub adapter to the car WITHOUT the spacer and steering wheel. Getting at the 27mm nut ... (more)
Posted : 1 June 2005  
 
Steering Wheel Removal and Installation
Model : Porsche Category : Interior - Steering Wheel
... horn button assembly. This is usually attached with an insert-type wire connector. Once the horn button assembly is removed, access to the center nut may be attained, as shown in Figure 2 on a 356. If you happen to own an impact wrench and air compressor, then the process of removing this nut is quite simple. However, if you're like the rest of us, and lacking both money and garage space, you ... (more)
Posted : 1 June 2005  
 
Brighter Instrument Lights for your Porsche
Model : Porsche Category : Interior
... be done in just a few minutes’ time. For a 911SC, you will need a total of eight 12 volt, 2 watt bulbs—“indicator lamps”, as they are termed by Osram, one of the manufacturers. To begin, pull the instrument from the dash. In the early cars, before the early 70s, this takes a bit more work, because the instruments are held in the dash with a U-shaped bracket, which must be ... (more)
Posted : 1 June 2005  
 
Interior Restoration: Starting the Project
Model : Porsche Category : Interior
... seat covers and thinking they weren't all THAT bad.I had been keeping an eye on Rennlist parts want ads when I came across one for a complete seat of perfect black leather seats. I emailed the guy for some pictures and found out that he was only a 40 minute drive from where I live. I went over took a look at the seats and as he said they were perfect and so $700 lighter I left with my ... (more)
Posted : 1 June 2005  
 
VDO Clock Repair
Model : Porsche, 914 - Series Category : Interior
... resolder the connection. To do this correctly, you need to use a low temperature solder (specification is solder with a fusing point of 120C or 248F). Where to find this? I don’t really know. I had some low temperature solder laying around which came in strips and was designed to be wrapped around a wire and then melted with a match. It never worked good like that, but it worked fine ... (more)
Posted : 1 June 2005  
 
Refinishing Fuchs Wheels
Model : Porsche Category : Wheels and Tires
... also work fine. I think I used 180 grit paper to remove the anodizing on the spokes and then followed up with 240 grit. This hard coating will dull the sandpaper very quickly, so change paper often. Now that the anodizing was gone from all of the surfaces that I wanted to polish, it was time to start hand sanding. I started with 340 wet/dry sandpaper (all the hand sanding was done wet). Then ... (more)
Posted : 1 June 2005  
 
Fuchs Wheel Polishing 101
Model : Porsche Category : Wheels and Tires
... time so you don’t have to go back and change out the buffs a gazillion times. Put some of the 80 grit grinding paste on a spinning buff. Allow it to sit for a few minutes until it is dry or almost dry. The paste will not cut nearly as well if it is used wet. When it is dry start buffing the anodized areas of the wheel. Only do a small area at a time. Let the drill and the compound do the ... (more)
Posted : 1 June 2005  
 
Wheel Painting
Model : Porsche Category : Wheels and Tires
... and smooth it gently but firmly. Don't press hard, or when you remove it, you'll pull up some of the silver. After masking the edge, then mask over the rest of the area. Step 8. Then, rinse the floor down gently with water. It will help keep the dust down when you paint. Spray your color coat according to manufacturer's instructions. I used a custom mix PPG color to match my sidestripes and ... (more)
Posted : 1 June 2005  
 
Cookie Cutter Paint Removal
Model : Porsche Category : Wheels and Tires
... to 45 minutes. You will see the clear-coat bubbled up like in the following photo: Step 5: Once it has bubbled up, take the steel wool and wipe the clear-coat off.Step 6: Keep rubbing the clear-coat off with the steel wool. This part is the easiest part because the clear-coat seems to be pretty weak. Step 7: Once you remove all of the paint stripper you will notice that the clear-coat is ... (more)
Posted : 1 June 2005  
 
Concours Corner: Polishing Alloy Wheels
Model : Porsche Category : Wheels and Tires
... with water. You are going to use the same technique as color sanding – only you are doing it on aluminum instead of paint. Keep the water nearby as you are going to dunk the sandpaper into the water frequently. Using an even motion, sand the area that is scratched, plus some of the surrounding surface. There are special rubber pads that can be purchased at automotive paint stores, that work ... (more)
Posted : 1 June 2005  
 
Targa Top Recovering
Model : Porsche, 911 - Series Category : Exterior
... there was plenty of extra material to grab on to on the sides to stretch the top. Removal of the hardware is pretty straight forward. Being anal about these things (and not wanting to find out later that there are specific left and right parts) I used masking tape to identify the parts.When removing the clips you need to be aware of the "floating" nut plate that is behind the panel ... (more)
Posted : 1 June 2005  
 
Concours Corner: Targa Top Reconditioning
Model : Porsche Category : Exterior
... color. I bought some warm gray and bottle of black. I also purchased a small sponge with a handle to apply the paint with. Now it is important to get a sponge that is about the same width as the rubber. This makes the paint easier to apply evenly. Now comes the tricky part. You do not want the paint to go on to thick, all you are trying to do it enhance the color of the fabric already there. I ... (more)
Posted : 1 June 2005  
 
Concours Corner: The Basics: Washing Your car
Model : Porsche Category : Misc
... wash your Porsche, make sure you get the valance, running boards and under the rear bumpers. These areas actually collect more dirt than any other place on your Porsche – unless of course you’ve been parked at the beach with a group of mischievous seagulls using your precious Porsche for target practice. Rinse the surfaces thoroughly with a hose and immediately start drying the ... (more)
Posted : 1 June 2005  
 
Detailing
Model : Porsche Category : Misc
... been a fan of chamois, but this is a different product. It really soaks up the water and doesn’t leave little droplets of water on the paint the way a cotton towel does, and there is no lint. Also, it doesn’t seem to pull the wax off the paint like a traditional chamois. These two items do an excellent job of drying the car, and they do it very quickly. If you do use cotton towels, ... (more)
Posted : 1 June 2005  
 
Making Your Window Molding Look New!!
Model : Porsche, 914 - Series Category : Exterior
... at all times. If you don ‘t, you will probably end up with more scratches than you started with.5. While you are sanding, continue to dip the sandpaper into the bucket of water. This helps clean any build up from the paper. The Basic H water also acts as a lubricant which makes it a lot easier to sand.6. Repeat steps 4 and 5 with each grit of sandpaper.NOTE:Remember that with each ... (more)
Posted : 1 June 2005  
 
Concours Corner: Rubber Strip Conditioning
Model : Porsche, 911 - Series Category : Exterior
... I used to use this on the bumpers and tires. It was too difficult to use on rubber stripping, as you had to rub it off just like wax. It would just be my luck I would be rubbing off the wax on the stripping and take half the stripping off because I got into my work too much. Black Chrome – This is my current product of choice. It gives the rubber a satin look and does not come off with ... (more)
Posted : 1 June 2005  
 
Concours Corner: All About Bras
Model : Porsche, 911 - Series Category : Exterior
... 911E every road trip. The bra will also minimize the more damaging chips that can occur. All it takes is for a small rock to get kicked up into the air and you traveling at a rate of speed much faster than said rock. Voila, a major chipping has occurred! If you had a bra on the car, chances are the damage may not be totally averted, but certainly minimized. Bra’s are sometimes cumbersome ... (more)
Posted : 1 June 2005  
 
996/Boxster Bra Installation
Model : Porsche, 996 - Series Category : Exterior
... may wish to “roll” the front of this piece down slightly so the felt edging is not exposed when the hood is closed (Figure 3). The bumper piece has one small hook in the center with a cylindrical retainer on each side. These two retainers fit into the space between the hood and the top of the bumper cover when the hood is closed (Figure 4). Fasten the small hook in the center first ... (more)
Posted : 1 June 2005  
 
911 Alignment Methods
Model : Porsche, 911 - Series Category : Suspension
... to 1.5 degrees negative in the rear, and degree less negative in the front (more if you’re serious about handling). If you don’t have a scientific calculator handy, you can approximate the measurements for a 15" or 16" wheel by using 4.5 / 32" for each one-half degree. (For our metric friends, about 3.5 mm per half-degree camber). The front of a 911 (or most Porsches) is ... (more)
Posted : 1 June 2005  
 
HOME TOE IN/OUT GAUGE CONSTRUCTION AND USE AND CAMBER MEASUREMENT
Model : Porsche Category : Suspension
... Toe measurement 11/16 inch or 0.6875 inch = Toe angle 1.64152 degrees Toe measurement inch or 0.75 inch = Toe angle 1.79079 degrees Toe measurement 13/16 inch or 0.8125 inch = Toe angle 1.94008 degrees Toe measurement 7/8 inch or 0.875 inch = Toe angle 2.08938 degrees Toe measurement 15/16 inch or 0.9375 inch = Toe angle 2.23869 degrees Toe measurement 1 inch = Toe angle 2.38802 degrees 3. ... (more)
Posted : 1 June 2005  
 
911 Camber Strut Brace Install
Model : Porsche, 911 - Series Category : Suspension
... off with a stiff putty knife. (figure 6 and figure 7) Rotate the shock stem so the keyway is inboard. It must line up with the tab on the camber brace mount. Make sure you pad the pliers when you do this, so you don’t mar the threads on the shock stem (figure 8). Test fit the camber brace bracket on the shock tower. The left and right sides are different, so make sure that the part of ... (more)
Posted : 1 June 2005  
 
Fikse Wheels & Suspension Upgrade
Model : Porsche, 911 - Series Category : Suspension
... Yokohama A032Rs weighed in at 43lbs for the fronts and 45lbs for the rears. I'm still glad I got the Fikses as cast wheels would have added even more unsprung weight.Click on thumbnail to view full-size image Before upgrading suspension and wheels... ...and after. The FM/10s look pretty good. Front wheels: The old vs. the new. Rear wheels: The old vs. the new. I really like how the screws are ... (more)
Posted : 1 June 2005  
 
Bleeding Brakes
Model : Porsche, 911 - Series Category : Brakes
... can become dislodged and cleared out by the quick rush of brake fluid when you press on the brake pedal. The procedure for bleeding the brakes using the brake pedal is pretty straightforward. Attach a small rubber hose to the brake caliper nipple and let the other end hang inside an empty container. Ask your assistant to firmly and quickly press on the pedal 3 times, and hold it down the ... (more)
Posted : 1 June 2005  
 
Upgrading to a 1.5 HP Starter
Model : Porsche, 911 - Series Category : Electrical - Starter
... starter on my little blue turbo car I realized the need to up-grade my old starter cable. I bought a good used cable and started the project by disconnecting the battery (installing a 9 volt radio code saver in the cigar lighter). Remove the driver’s seat, carpeting on the floor, center tunnel cover, console, floor board under the pedals, and trans. tunnel cover. The trunk carpeting needs ... (more)
Posted : 1 June 2005  
 
Installing an MSD Ignition System
Model : Porsche Category : Electrical - Ignition
... a few dollars from places like AutoZone. ! New spark wires will most likely require that your spark plugs have the screw-on slip-over connectors which you probably removed and threw away when you installed your plugs, since normal VW type wires slip onto the threaded rods at the top of the plugs. So, either find four of those spark plug top thingees, or buy a new set of plugs. You can consider ... (more)
Posted : 1 June 2005  
 
Improved Cooling for your Porsche—Cheap!
Model : Porsche Category : Engine - Cooling System
... is a finned aluminum jacket that slips over the oil filter(Figure 1). It is secured by a clamp to the outside of the filter, which provides full surface contact and allows maximum heat transfer. Considering that all of the oil in your Porsche goes through the filter more than once a minute at freeway speeds, the oil filter is an excellent location to add cooling capacity. Bench tests, ... (more)
Posted : 1 June 2005  
 
Truction Control Kit
Model : Pontiac, Grand Prix Category : Misc
... to the interior of the car to a switch. At the fuse-box, add 2 wires where the fuse enters and "reroute" them to a switch in the inside of the car. Splicing into this connection enables the switch inside the car to activate or deactivate the TCC. This mod should be for track use only as it disables the ABS as well. Now here is the masterpiece as I call it. Previously I had one ... (more)
Posted : 19 May 2005  
 
Strut Tower Brace Install
Model : Pontiac, Grand Prix Category : Suspension - Shocks/struts
... that you use caution when tightening the bolts. As a suggestion, start at a lower torque spec setting for a few days (how about starting at 25ft/lbs), and check often to see if the bar or bolts come loose. If so, increase your torque by an additional 5 ft/lbs until they sit properly and do not loosen. Installation procedure for the front STB: The front STB took some work and about 1 hour to ... (more)
Posted : 19 May 2005  
 
O2 Sensor Spoof
Model : Pontiac, Grand Prix Category : Exhaust - Oxygen Sensor
... Don't be another fool getting ripped off. Note: Credit for this mod must go to Rodney Chalker. How it is done: First thing you need to do is go to Radio Shack or just your local electronics store for a pack of 100k resistors. You will need only one. Find the O2 sensor on the U-Bend or wherever you may have placed it. Unplug the harness from the O2, bend the tabs up on the heat shield holding ... (more)
Posted : 19 May 2005  
 
Replacing the Thermostat
Model : Pontiac, Grand Prix Category : Engine - Cooling System
... from the system (save it into a clean container, it can be reused... I found that I was able to do the install without draining, but be prepared for a little spillage... top off if needed.). - Disconnect the radiator hose form the thermostat housing - Remove the bolts from the thermostat housing - Remove the thermostat housing and gasket - Clean all mating surfaces - Install the thermostat ... (more)
Posted : 19 May 2005  
 
Radiator Fan Mod
Model : Pontiac, Grand Prix Category : Engine - Cooling System
... the switch. Make sure the diode is as in the picture below. Number 2 pin has to be grounded to the car. Step 3: Open the fuse box under the hood. You must now run two wires from the relays to the switch under the dash. (There is a rubber plug in the fire wall in front of the brake pedal.) Strip wires 1/2 inch and connect numbers 1 and 3 pins to the 1 and 3 marked in the fuse box in the pictures ... (more)
Posted : 19 May 2005  
 
Wrapping the Cross-Over Pipe
Model : Pontiac, Grand Prix Category : Engine - Cooling System
... and held in place by a metallic retaining strap (like the kind that holds the hose to the back of the clothes dryer), and looped all the way to the end of the crossover tube's length, where another retaining strap holds it all in place. Total installation time is around 15 minutes with 2 people doing it (one pulling the excess wrap and one doing the wrapping). I initially hear that this mode ... (more)
Posted : 19 May 2005  
 
Rear Spoiler Mod
Model : Pontiac, Grand Prix Category : Exterior
... step (mine was VERY dirty and cruddy underneath). 4) Going to the trunk lid, clean thoroughly. If there are any scratches in the paint, fill them in with touchup paint. This might take 2 coats (mine did) and a few hours to do well. If your car is not black (like mine), you might consider painting the gaskets to match your car's paint at this point in time as well. Let dry completely. 5) Place at ... (more)
Posted : 19 May 2005  
 
Adding Extra Gauges
Model : Pontiac, Grand Prix Category : Interior
... comes out fairly easy. The rest of it is up to you depending on what type of gauge is being used, either mechanical or electrical. I would suggest an electrical since only a single wire needs to be run from the sending unit to the gauge. Whereas the mechanical one would require tubing to be run into the car with the chance of a leak. Warm oil on the carpet inside the cabin is not a good ... (more)
Posted : 19 May 2005  
 
Custom Grills
Model : Pontiac, Grand Prix Category : Exterior
... by three screws on each insert. The finished look is totally stock looking and professional. Besides, I think they look very cool! Total install time: 10 minutes! Here's how it looks (don't mind the bugs!): I first saw this mod on the GTP of Mike Bouchard during his attendance of the Montreal GTP gathering (July 25, 1999). I expressed interest in also getting a set. This gentleman was NICE ... (more)
Posted : 19 May 2005  
 
Reflective Lettering
Model : Pontiac, Grand Prix Category : Misc
... many colour options) the lettering kits are subtle during the day, yet at night shine a brightly as they reflect light from external sources (like the headlights of someone who just received a can of "whoop-ass" and is looking at the "PONTIAC" logo disappear into the distance at night). The front and side lettering kits shine a distinct gold colour when you hit the right ... (more)
Posted : 19 May 2005  
 
Caliper Painting
Model : Pontiac, Grand Prix Category : Misc
... for the rear calipers As the calipers are drying, time to remove the rust from the rotors The left one is cleaned, the right isn't. See the vast difference? I used a cordless drill and rust remover pad and some scotch pads to get to the tighter places. Do NOT use a wire pad as it will damage the rotors! Here you can better see the left one that has the rust removed After they're all cleaned, I ... (more)
Posted : 19 May 2005  
 
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