924Board.org

xpernet · Last edited by xpernet on Mon Jun 27, 2005 12:31 am; edited 1 time in total

Hey guys!!

There is something weird happening in the 924. While we were driving today, heat started to pour into the car. I also smelled exhaust fumes, and my eyes hurt me. This has been eversince the heater core blew up and got bypassed. We checked if there is an exhaust leak, but there isnt.

Any suggestions ??? Its like a sauna in there!!!!

thanx in advance

xpernet
_________________
1977 Porsche 924
Sunroof Delete
Megasquirt II EFI & EDIS
Carrera GTS / 944 Body

"If one does not fail at times, then one has not challenged himself." Ferdinand Porsche

Smoothie · Posted: Sun Jun 05, 2005 5:51 am Post subject:

Were you left with an opening in the firewall (where the heater hoses go through) when the heater was bypassed?
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

xpernet · Posted: Sun Jun 05, 2005 5:54 am Post subject:

Ozzie · Posted: Sun Jun 05, 2005 9:03 am Post subject:

The early 924 exhaust manifold was prone to cracks. As this is not far from the holes in the firewall this may be your problem.
I'd check the manifold to heads studs as well and around the turbo if you have one.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

Smoothie · Posted: Sun Jun 05, 2005 10:34 am Post subject:

Obviously closing the opening in the firewall should be done asap. That should fix both the heat and most of the exhaust smell/burning eyes problems. If there's no exhaust leak, it could be fumes from oil burning off the engine and getting in through the firewall opening. I'd try a piece of sheet metal and silicone sealer to close the hole.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

augidog · Joined: 03 Mar 2003 Posts: 1360 Location: New Jersey

Ozzie · Posted: Sun Jun 05, 2005 2:53 pm Post subject:

I think pre '80 but you'll have to do a search on here to be sure.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

xpernet · Posted: Sun Jun 05, 2005 9:31 pm Post subject:

Thanx for your replies! I have fixed the heat problem, by stuffing a peice of cloth into the pipes of the heater core.

But i still smell exhaust fumes, especially at the driver's side.

Could the rear hatch be leaking exhaust air into the car ????

xpernet
_________________
1977 Porsche 924
Sunroof Delete
Megasquirt II EFI & EDIS
Carrera GTS / 944 Body

"If one does not fail at times, then one has not challenged himself." Ferdinand Porsche

Khal · Posted: Sun Jun 05, 2005 9:36 pm Post subject:

xpernet · Posted: Sun Jun 05, 2005 9:41 pm Post subject:

Actually i did. I Closed every single opening in the firewall, hence no heat.

xpernet
_________________
1977 Porsche 924
Sunroof Delete
Megasquirt II EFI & EDIS
Carrera GTS / 944 Body

"If one does not fail at times, then one has not challenged himself." Ferdinand Porsche

Smoothie · Posted: Mon Jun 06, 2005 12:37 am Post subject:

We just went through (and some are still going through) this in another series of threads dealing with one problem, but it won't take long to cover and I can't with clear concience ask anyone to read through that other stuff.

Yes, the rear hatch can leak exhaust in. If so, a new seal might fix it, but when I noticed it when my car was new [to me], I just let the gas out of the hatch struts - that let the hatch sit down heavier and tighter*. It took care of the leak and I never replaced the seal. With that, there can still be a small gap at bottom-center where the seal ends meet - fill that with a small strip of foam or whatever.. No need to let the gas out of the struts - just disconnect them to see if it helps.
* - Hatch struts can also cause some twisting of the hatch frame. That can do two things - seperate the glass from the frame and open gaps between the hatch seal and car body. Disconnecting the struts eliminates both of these problems as well.

Other possible openings are around the shifter, the small drain hole at the bottom of the spare tire well, drain holes at both deep pockets behind the rear wheels, if the rear lights aren't sealed exhaust can come in there, if the fuel filler hose cover behind the carpet in the luggage compartment was ever removed and not resealed..., the fuel level sender cover... those are the most likely places to find a leak. Of course in addition, you could have other holes anywhere from damage and rust - any hole in the bottom or the firewall will let exhaust in. -And even if the exhaust system is sealed perfectly, you'll still get exhaust in if the tailpipe end isn't extended back far enough. I even got fumes apparently in through the door windows after I replaced my muffler recently - until I extended the tailpipe further back.

[A couple more possibilities are: (1) the seal at top of the firewall is not good, letting fumes from the engine compartment back into the area of the vent air intake and (2) a bad seal where the antenna wire comes in.]
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

xpernet · Posted: Mon Jun 06, 2005 2:24 am Post subject:

i didn't pay attention to those other posts on the board. I have exams and i am in a rush, plus i am helping my parents in packing and cleaning up the house cuz we are moving to canada. So its a mess around here.

Now, as for the hatch, my struts are dead, so it seals every thing good. Although, at the top of the hatch, there is air leaking in, and above the keyhole too. My Tail lights arent sealed, so i need to seal them now. My rear hatch area might be the problem. The fuel sender unit is sealed. I think i should check the drainage.

Ill also check the shifter area.

Again thank you Smoothie for your help

! You are da man

xpernet
_________________
1977 Porsche 924
Sunroof Delete
Megasquirt II EFI & EDIS
Carrera GTS / 944 Body

"If one does not fail at times, then one has not challenged himself." Ferdinand Porsche

xpernet · Posted: Mon Jun 27, 2005 12:29 am Post subject:

Sorry for a late reply

I have finally fixed the exhaust smell, that was leaking into the cockpit.
Its was my door panels. I have two speaker holes (with perforated speaker covers) on each door that had no speaker!!!! So i just took a peice or cardboard, covered the holes and installed the covers back on.

I think that timstar should check his doorpanels, in case if he didnt fix the problem!!

No more exhaust smell!!!!

xpernet
_________________
1977 Porsche 924
Sunroof Delete
Megasquirt II EFI & EDIS
Carrera GTS / 944 Body

"If one does not fail at times, then one has not challenged himself." Ferdinand Porsche