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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 04, 2017 2:25 am 
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It's because it's magnesium and the metal properties have bigger honeycomb holes compared to aluminium, It's also dependant if they chemically stripped
and / or shot blasted it ? also did they pre heat to 200degs, or just coat it cold etc..etc.. all of these factors will help or worsen the possibility of the coating
to bubble when heated and cured.... Lastly are they are industrial powdercoaters? if so this powder is cheap and thick and doesn't flow as nice as the expensive stuff.



R[/quote]

Didn’t realise the cam cover was magnesium. Powder coaters are not an industrial set up, they coat all sorts of stuff- motorcycle frames & wheels, bicycle parts, aforementioned Ferrari parts and whatever else people want coated.
Cover was aqua blasted as it was in a poor state to begin with. I have no idea if it was pre-heated or not :roll:


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 04, 2017 4:44 pm 
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blackadder30 wrote:
Thanks Martin :D I have been warned not to get it too close otherwise the flywheel chews the end of the sensor off :shock: which wouldn't be good :lol:

My plan was to use the mark left on the housing by the left hand bolt to basically refit it in the same position as it was originally in... All the best laid plans though may not come to fruition... Watch this space!


I'm pretty sure my 944S2 no spark problem is also related to sensor failure as have swapped DMA relay etc. As the 3.0L S2 has a single sensor like your 968 I'm assuming its all mounted identically to yours and I'm going to have the same bundle of fun - I can't even see it down there!

If like you I can't get the sensor to slide out of its housing and both have to come off then I am slightly confused why marking the housing position still led you to have to reset the gap? Is getting the gap right easy?

Cheers Rob

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 04, 2017 9:36 pm 
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There is a trick of glueing a penny/cent to the end of the sensor to get the setting but don't leave it on. Have a look at Clarkes. Mine slid out easlily on the 944 but the 993 was was totally seized in and needed a new clamp. OPC set it using an oscilloscope.

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 04, 2017 9:41 pm 
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Hi Rob, it was a complete Pita to do but that was largely through making it up as I went along - a journey of discovery!

The sensor is very tight in there so I would be surprised if it comes out on its own if yours is anything like mine was... The lack of long extension bars to get leverage on the 6mm hex Allen key was my down fall....

The trick with the penny on the end is a good one although I used the same setting one the new one as was on the old one and it wasn't correct....

Resetting the gap was more about trial and error given the horror stories I've been told of getting the sensor too close to the flywheel and it being chewed up on the first turn of the key.. Given the cost of these sensors, I wasn't taking any chances on that...

It's easy to undo and tighten after it's been off so setting the gap isn't difficult...

I'll put a How To guide together once it's all done :D

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 04, 2017 9:47 pm 
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from memory when I did mine I used Clarkes garage advice and glued a 0.8mm washer on the end of the sensor. Slacken off the sensor mount bolts, fit the sensor/washer into the mount and refit the sensor bolt, then gently press down until the sensor/washer touch the flywheel starter teeth and nip up the sensor mount bolts. Take the sensor back out and remove the washer with a sharp blade - it will ping off easily. Stick the sensor back in.

as previous posts they are hard to get at, so remove, unclip, disconnect anything that's easily moved to make as much room as possible and either lie on top of the engine or put a strong box at the side of the car so you can lean right in. Get comfy(ish) before you start and the job will go easier.


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Tue Dec 05, 2017 11:46 am 
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Thanks all for encouragement and words of advice. I'm just going to have to get stuck into it over Christmas. A Howto would be wonderful, although I feel more confident now after reading this thread and seeing the pics than I did a week or so ago when I was diagnosing the problem!

I might be investing in some good quality hex key square drive sockets first so that I can use a range of joints and extensions from my socket set. New tools over Christmas always seem right to me :)

Cheers all

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Fri Dec 08, 2017 10:01 pm 
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Having better tools than I had will be invaluable to you Rob!

I've not been able to get out to the 968 again to try the washer on the end trick but hopefully this weekend if I can stop being a wuss and brave the cold :lol:

In the meantime we had some fun in the snow around Pott Shrigley, Kettleshulme and Disley this afternoon.... Rothmans was perfectly suited to this while the winter wheels were bring fitted to the Boxster :grin:

Image

Image

Image

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1993 968 Coupe - Guards Red needing TLC
1989 944 S2 Cab - Guards Red for summer fun
1982 Rothmans 924 2.0 NA - the best livery ever
2004 Mazda MX5 - Silver for everyday
1979 Austin Healey Frogeye - Old English White


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 11, 2017 11:37 pm 
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I bought my 944 on saturday and blew the engine up today! :shock:

Something internal has happened and punched a hole in the rocker cover.

Need to take a look as soon as I get 5 mins


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Tue Dec 12, 2017 1:10 am 
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alienb4ndit wrote:
I bought my 944 on saturday and blew the engine up today! :shock:

Something internal has happened and punched a hole in the rocker cover.

Need to take a look as soon as I get 5 mins

That's seriously bad luck :( was it a dealer or private sale? I'd be tempted to speak to the seller.... Good luck :)

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1998 Boxster 2.5 - Silver for everyday
1993 968 Coupe - Guards Red needing TLC
1989 944 S2 Cab - Guards Red for summer fun
1982 Rothmans 924 2.0 NA - the best livery ever
2004 Mazda MX5 - Silver for everyday
1979 Austin Healey Frogeye - Old English White


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Tue Dec 12, 2017 9:44 am 
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alienb4ndit wrote:
I bought my 944 on saturday and blew the engine up today! :shock:

Something internal has happened and punched a hole in the rocker cover.

Need to take a look as soon as I get 5 mins


That is really bad luck. I recall that another contributor had a similar experience when he had the head gasket changed and one of the bolts inside the cam tower (The ones under the removable covers in the cam tower) was left loose. The bolt apparently came undone and was catapulted by the camshaft out through the cam tower housing. There are quite a few bolts in there so it would be very easy to miss one in the assembly process and it is also very easy to drop one inside during assembly.

As Blackadder says, you might want to speak to the vendor to see if any work has recently been done to the top of the engine and what assistance they can now provide to you.

They are great cars and very reliable when properly maintained so do persevere.

Good luck and keep us posted.

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Tue Dec 12, 2017 8:32 pm 
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I have called the seller and made him aware of the situation. Th head gasket had been replaced prior to me buying it so tje chances are that something was left loose. The seller is speaking to the garage tomorrow to get his opinion.
I'll update here when i have further news


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Wed Dec 13, 2017 6:57 pm 
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alienb4ndit wrote:
I have called the seller and made him aware of the situation. Th head gasket had been replaced prior to me buying it so tje chances are that something was left loose. The seller is speaking to the garage tomorrow to get his opinion.
I'll update here when i have further news


Hi

I've sent you a text - lets hope we can resolve this amicably as the forum may continue to be of use to both of us.

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Sat Dec 16, 2017 6:40 pm 
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Hurray!! 8) :D 8)

Got some time on the 968 this afternoon.... as the new Bosch ignition coil arrived in the week (£41 from fleabay)

Image

I thought I'd try this before messing any further with gaps, washers, sensors or any other crap that meant climbing over the engine and sticking my hand and arm into places they really wont go.... anyway, this is the result

https://youtu.be/sIdHFlUBCXk

There is a slight issue though.....

https://youtu.be/eAtx1BtkjZA

Even after warming up fully she wouldn't settle much below 1800rpm... and is slow to drop the revs after acceleration....

Image

Took her for a short test drive and she is so much more responsive than previously. Seems it could just have been the ignition coil after all but hey, with the issues she displayed it wasn't an easy one to diagnose... Anyway, I'm a step much nearer getting back on the road again now... just need to settle the revs...

I'll perhaps put my old ICV back on and check if that makes any difference.... other than the cam and crank sensors, that's the only other item I've changed to try to address this issue as its got worse over the year.

Any other ideas are more that welcome :D

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1998 Boxster 2.5 - Silver for everyday
1993 968 Coupe - Guards Red needing TLC
1989 944 S2 Cab - Guards Red for summer fun
1982 Rothmans 924 2.0 NA - the best livery ever
2004 Mazda MX5 - Silver for everyday
1979 Austin Healey Frogeye - Old English White


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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 18, 2017 9:40 pm 
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Pigging heater stopped working, well the thermostatic control did. I can get heat if I hit the defrost button and for a while if I turn the temp to max. Took the little fan sampler off gave it a good clean and checked the thermister all ok. Outside temp sensor ok. Am I missing something?

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 Post subject: Re: What did you do to your 924/944/968 today?
PostPosted: Mon Dec 18, 2017 10:26 pm 
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Four sensors on a 968

One under the bonnet RH end of the air box
One inside the mixing chamber in the heater box
One in the little fan
One in the ns door mirror

Or a bad connection on the back of the heater controller

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