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Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Per a suggestion of a "Porsche" (non-cert, but wrenching experience) mechanic in the area, I'm replacing the pair of sensors on the rear of the engine as a possible fix for my formerly intermittent (now nonexistent)sparking problem. The front one came no problem and I slid the new one in. The second one (rearward) has been nothing but a bitch. It's come up about 1" and won't budge further.
My fear is that this will snap off and leave an even bigger problem. If it does, would I be able to push it through into the bell housing? Is it retrievable in this case?
Yet another problem...

_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Paul · Posted: Wed Sep 21, 2005 1:47 pm Post subject:

You cannot push it into the bellhousing since it will hit the flywheel. Spray some pb blaster or WD-40 on it.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Thanks Paul. I didn't mention that it's been soaking in PB for 4 days now... I can get it to rotate at least.
At least you've confirmed that my fears of breaking it weren't unfounded!
Rick
_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

So now I've gone and done it. The top portion of the sensor has snapped off!

Man this thing is REALLY in there!

So what's a guy to do now?

And why are there TWO of the same sensors there anyway?????

_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Paul · Posted: Thu Sep 29, 2005 11:56 am Post subject:

Now you must remove the bracket that holds the sensors. I can email you a drawing if you send me your email address.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Paul · Posted: Sat Oct 01, 2005 8:50 am Post subject:

I sent you 4 pages.....
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Thanks again Paul. The documents were a great help. But as most service manuals are, they don't mention that there's no room to work in the area neccesary.

I finally got a chance to work on the car today and am STILL yanking my hair out!

Well I discovered that the locking bolt was missing on the sensor bracket. Perhaps this is why it had the starting issue...of course I've already spent $170 on a pair of new sensors. I'm wondering now if the bolt has fallen in the inspection hole, or tumbled clear over the bellhousing.

So now I need to remove the bracket so that I can remove the remains of the rear sensor. The whole top has broken off and the magnet has pulled out of the plastic. The rest is flush with the bracket and there's no room to work in there.

And now I can't get a 6mm hex on the pivot bolt since the ratchet hits the firewall! I can't even get my hands in the area neccesary to get a standard hex key in there! (Have I mentioned that there's no room to work in there?) My hands are not big by any means. I'm going to have to find about 2 feet of 6mm hex stock and bend it into my own wrench I guess.

Once again I wonder why I keep buying German cars....

If I've got to pull this motor I'll swap in a Chevy I swear! It's forcing itno this blasphemy!

_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Paul · Posted: Sun Oct 09, 2005 7:56 am Post subject:

I put the car up on stands and from underneath,use a long 3/8" extension with a U joint and the 6mm hex on the end.

Make sure you clean all of the gunk out of it and that you seat the hex firmly or you will strip it out.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Paul · Posted: Sun Oct 09, 2005 8:03 am Post subject:

BTW it is very helpful to have a second set of hands to help keep the tool firmly planted.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Thanks yet again Paul.

I though of this, but it looked like a blind operation. I'll have my wife hold it all together from the top.

It's clean as a whistle there as I drained a can of WD40 in that area cleaning and lubricating the sensors. I can only hope that the locking bolt isn't snapped or in the bell housing. I din;t hear any noises when it ran though.

It's fustrating having a car that you've only driven 6 miles in for the last 4 months!
_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Got the bolt out solo! On a whim I used a 1/2" length of 6mm hex stock on a 1/4 drive ratchet and a 6mm socket. J-u-s-t enough room to get my hand in and turn it.

Of course NOW the mount won't come off the pivot bushing because the broken part of the sensor is in the way!!!!

Arrrgh!

I let it rest and got some sleep... and I'll try again tomorrow morning...

It's been raining here for so long my canopy is leaking!

_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Lord Fester · Joined: 13 Sep 2005 Posts: 33 Location: Rhode Island

Well it FINALLY came out!

I had to collapse the roll pin the pivot bolt goes through to do it.
Once I got the mount out I had to clear the tubes out with a large drill bit.
I clamped the bit in a vise and hand turned the sensor bracket to hone out the tubes. I got it all together and it started right up long enough to see that the thermostat is stuck.

Oh well, that's an easy fix (I hope).
I HATE it when peole park cars for extended periods without starting them regularly...

Thanks again Paul forthe help.

Those docs gave me a reference to ponder on before I went using a hammer. (a tool to never be used without some foresight!)
_________________
'87 924S slushbox (nice tourer)
'87 VDub Cabriolet "hers"
'87 VDub Cabriolet "ol skool" mine
'82 Scirocco (organ donor)

Living the dream. One broken part at a time...

Paul · Posted: Tue Oct 18, 2005 11:49 am Post subject:

Congrats, I'm glad to hear it runs.

That was a good idea (collapsing the roll pin), one guy I know used a hammer and chisel to break the mount. Your way is better and cheaper!
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.