1985 Porsche 944

Ditto teaboy 's comments on the fuel hoses - very good job indeed - better than factory

I really don't trust some of the modern fuel lines out there - the ethanol in modern petrol either eats them or they aren't of a similar quality that they used to be - I replaced all the fuel hoses on my big green minicab back in 2014 (no leaks after 23 years at that point so was just preventative as I was getting it back on the road after several years semi broken) - had to replace one of them again last month - it was cracked everywhere and spewing out fuel after 10 years.....)

It's great how you've managed to turn this around in a short space of time, it'll be good to see the 944 back on the road soon

A month already! Ive got a small update, but thats "still to come". For now I'm just a bit giddy, last night I was at a very small event a Bicester heritage and Hertz team Jota had loaned their display car. I felt it would be rude not to park next to big brother.

So I lied a bit, mostly because I forgot. I also got hold of some tat. This was about 20 quid on the bay. But a lovely bit of history, its a european spec car. As you could never by a trim level this low in the UK. See if you can spot all the parts my car has, which this one doesnt. These items form the Luxary pack.

Anyone remember that fuel leak from March? You know the one that was a fairly easy fix, just before the engine blew up? Well now was finally the time to sort it.

I dropped the box, again, I'm a bit too good at this now.



And then the tank, I had done some research on this topic, to see if there were any obvious things to check. There were a few threads talking about fatigue cracks in the steel tanks. Particually around a pressing in the top centre. I checked mine and sure enough, the coating had bubbled right there. Had we found the culprit?



It would seem not, thankfully. I really didnt want to went into welding fuel tanks.



After a good look over, the tank seemed to be ok. This left me 1 one simple idea, pressure test it. I had no fancy kit for this. I used anything I had laying around to blank things off.







I huffed and puffed as best I could. The tank was expanding when I blew, I couldn’t hear any hissing and I was able to hold my thumb over the pipe and spray some soapy water around the joins. No bubbles. While it wasnt the most technical test, I was happy to trust the result.

The filler neck was looking at bit grotty, and the seal I took off was knackered, so I addressed this.











A cleaner, new seal.



Thats the tank about as "looked" at as I can get it. I'm content that it wont leak. So I wrestled it back in. Followed by the gearbox.

When I took the coupler off I noticed that the pinch bolts were starting to round, two fresh ones were ordered from OPC Hull.





Everything went in rather smoothly, and the exhaust it back on. As one would expect given how fresh and recent it all it. To this end I went for a ride to the petrol station and brimmed the tank. For this I had left the filler neck cover off, so if it were to leak, I could spy from where. But I am pleased to report, not a drop was spilt.

I went for a nice drive afterwards to slosh it round and see if I could make any fall out. It simply refused and I wore a smile. This cheered me up no end as the MOT was impending.

A week later after a good wash.



I set off in the direction of, I handed the tame tester a packet of biscuits and my car keys. This was to in no way try and persuade him to print a pass ticket.



The first task was to check that gas was coming out of the pipe at the back. Computer says no.



Some grunting and chuntering later, we decided to do the rest of the test and see if the computer would have got its act together by the end. It flatly refused and for the first time in my life, the test station failed the MOT rather than my car.



They were fully booked up for a few days, so I will have to return another day and see if the garage will pass next time.

On the way home I had a strange knocking noise, which I assumed would be something id forgotten to do up the previous weekend. I ducked under to check and all was well. My next thought was the jacking handle, its wedged with some foam, maybe the foam has fallen down? To check this the spare wheel needs to come out. Oh wait, the spare wheels loose. That'll sort that out then.




With all that out the way and summer finally here, went to festival on the unexceptional at the weekend. Not the right car I know, I took the fasty last year. I put this little display in my boot of the tat ive gathered over the years.

It’s a conspiracy, man!

What have I got to tell you then? Its been a week. One with a lot of achievement it has to be said.

Last Sunday afternoon after id done some more painting in the hallway. Which needed to dry, I figure it was a good time to find out why it was having a wee wee. Once jacked up I still couldn’t see directly where it was coming from, but the end point, on the bottom of the power steering pump bracket could be fed from 1 of 3 places. First of all, the top rad hose which feeds into the head. This can easily be checked from above and was. All dry. 2, the water pump, can’t be checked with the timing belts on. 3, a crack in the block. At this point a water pump was the least painful hope.



Fluid out and sleeves rolled up then. I spent about 3 steady hours getting down to the pump. As is always the job with this, its been apart enough times that I never have a stuck bolt to fight.





This all the belts, pulleys, sprockets and guards out the way, were doing the nitty gritty. And that black dirty under the water pump pulley was the smoking gun I was looking for. That was tiny bits of rubber, showing the pump had been weeping sticky antifreeze and the notchy pump was obviously wearing the belt. So better it went now, rather than later and took the belt with it.

Content I had found the problem I removed the pump and found what initially shocked me. Rusty mounting studs, my first look told me they were very tired. I ordered some replacements.



After a few conversations with friends, they said clean em up and leave em alone, they aren’t as bad as I thought. I took a step back and looked at them a few days later. They were indeed right, a bit of surface fuzz but that was all. I did attempt to remove one, but it was stuck fast and I didn’t want to get into snapping one off and then having to take the front end apart in order to make room for a drill.

So with my lesson learned, the recommendation is that the belts are changed every 4 years, the pump and tensioners every 8 years. With the latter nudging on for 11 years. I ordered a pump and a set of tensioners. Along with a new timing belt, the balance belt is new enough and non critical enough that reusing it will be ok.

A new pump from OPC was knocking on for £700, which is too strong for my tasted. I ordered the tensioners and belt from them though as the prices were competitive. Pump wise I was pleased to find there is much more choice than 11 years ago and good quality at that.

I got my hands on GEBA for under £200 on 48 hours delivery.





As ever, its not just a straight fit, this needed painting to A) match the rest of the engine, and B) not look like corroded aluminium in 12 months time.



I dusted this on over a couple of evenings during the week. I also cleaned down the mating faces on the block and had a general clean up around the front end. With all the prep done. I had planned to get up early Saturday and knock it out. Id estimated 4 hours to do it. So being done before lunch and then having a run would be ideal. This is a rare occasion where I out ran the Gant chart. Friday evening I came home full of vim. After tea I decided to crack on.



Not the most exciting thing to be photographing.



So I didn’t bother for the rest of it. But over the next 2 and a half hours I built it back up. Set the belt tensions, then I took a step back fora drink. Doubled checked everything and turned the key.



We have life! I set the balance belt by ear, rather than by tension figure and let it run up to temperature. The rad fan kicked in and then back off again. I was happy and closed the garage door for the evening. There was however one casualty of the previous few hours. When changing direction of my ratchet, the tang broke off



Luckily as its the fancy stuff, i should be on for a free replacement.

Saturday morning rolled round, I tret me sent to a lion, but at 9am I still couldn’t help but go check the car. I bled the rad, followed with some DIY and then went for a run to Aldi for Mrs Broady. Everything worked as it should. I gave it a final afternoon check over and then as the sun was setting over the wolds I went for a sundowner run.

It may test my patients at times but fudge me that’s a handsome devil.