My 1987 Porsche 928 S4, 5 speed
Once
You Are There - Intake Manifold
Parts For Intake
Refurbish (from Bernie's
site )
OK, here is what to expect.
Intake runner boots - 2" straight couplers for the small and 3" bulge
couplers for the large. Available through Turbonetics (go to links
page). The 2" ID boots come in 3" lengths. The S3 only needs 1.5"
boots. Buy 4 and cut them in half. Expect to pay around $8.00 each for
the 2" boots. The 3" bulge coupler on the passenger side goes on as is.
The one on the drivers side has to be shortened.
Clamps - I
used T-bolt clamps on the 3" couplers and regular old Trident worm
clamps on the 2" couplers. I tried T-bolts on everything but it was
really busy and I didn't thin it looked clean at all. You may have a
different opinion.
Intake Gasket Kit
- Available from 928 International. This kit gives you a lot of the
gaskets you will be replacing. Cam covers, cambore seals, o-rings,
sparkplug socket gaskets, etc. Expect to pay around 150.00 for the kit.
I think???
Fuel Injector seals
- Once the injectors have been removed, you will need to replace all of
the o-rings. Again from 928 international. If I remember correctly, you
get three o-rings in each 5.00 package. So buy 6 kits and you will have
enough to replace all your seals.
New injectors
- I didn't do this with mine this time around but I wish I had. It will
cost approx. 200.00 to replace your injectors with new ones. Flowing
and matching your old injectors cost about the same so this is a no
brainer. You will still need the injector seals though.
Intake gaskets
- These are a rip as far as I'm concerned. You will be buying gaskets
from 86.5 models. These are decent gaskets, much better then the
originals but they are around 30.00 each and you need 4 of them (2
cylinders per gasket). All other MY gaskets cost much less.
Camcover Breather
Hoses - Actually, I replaced just about all breather hoses under
the intake. The only ones I didn't replace were ones that seemed as
soft as new ones and showed no signs of bulge or split. These hoses can
get expensive. One hose cost me 30.00!! If you have the dough
available, best to replace them all.
Throttle Body
Mounts - 2 of my 3 mounts were split. Again, expensive for what
they are - Got new ones from DEVEK. There are 2 of one size and 1 of
another. Check to be sure that you get the right ones.
Vacuum Lines
- I replaced all my vacuum lines with silicone ones. Again, this came
from Turbonetics but I still need to find out what the ID is. A friend
gave me the hose so that's why I don't know. I did have to re-use some
of the old elbows. I had a few that were in really good shape so I
didn't mind reusing them.
Powder coating
- Applied Powder did all my PC work. It costs around 150.00 to do the
black or any straight color. The candyapple parts were over 200.00
because of the 2 step process. I think I would have also considered
some nickel plating as well. A friend has some of his parts done that
way and they look really decent.
Lots Of Stainless
Steel Fasteners - I replaced every fastener I could with
socket head cap screws. I don't have all the sizes. What I did was
after
I tore the whole thing down, I went to Fastenal and had them match all
the fasteners. This makes a big difference with regards to the
"finished" look of the job. Don't forget to get stainless steel washers
as well.
Check Valves
- Since I had the camcovers off, I replaced the oil check valves in the
cam chain tensions. I think these were about 30.00 each.
Ignition Wires
- I think these are MSD wires. They cost 275.00. They come precut and
ready to go on. I went with the S4 wire cut so I could route the wires
across the bottom of the camcovers as opposed to the original top
route. Looks much cleaner.
Outside of that, you will need anti seize on all fasteners, silicone
for
sealing all of your gaskets, brake cleaner or carb cleaner to
completely cleanup the engine prior to working on it. Tons of rags - a
box of latex gloves - etc, etc
VERY IMPORTANT
- Clean as you go!!!!! Get all the dirt / grime etc. away from parts
before you remove them. Despite my best efforts, I still managed to get
a little dirt into the valves. You can't get it out either. You just
have to grin and bear it when you fire up again.
Also expect some unforeseen problems. I had a bolt that broke off in
the head. I lost a couple of Bosche connector clips. I had a couple of
spots of wire insulation break on me because it doesn't want to bend
anymore. Just be very careful and delicate with all parts as you
disassemble.
If I come up with more info, I will post it.
Go to the links page and you can get to all the vendors that I used
with
the exception of Fastenal. I will post their info shortly
Cheers
Bernie
Thanks Bernie!