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doomer77 · Joined: 10 Jan 2006 Posts: 266 Location: Huskvarna, Sweden

is this a repair that is possible to do yourself? if so, how?
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Why drink and drive when you can smoke and fly?
Carpe diem. and if that doesnt work; get drunk!

1980 924 n/a - engine swap begun
1989 Volvo 480ES

chris24 · Posted: Mon Jan 30, 2006 6:38 am Post subject:

Done a head gasket on a similar engine, but never a 924. So "Yes" should be the answer with a bit of time and patience.

This search result may be quite useful.

http://www.924board.org/viewtopic.php?t=15495
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1983 - 924 (185K miles) - not mint
1985 - 924 (148K miles) - mint
1990 - 944S2 cab (52K miles)

fergie · Joined: 21 Sep 2005 Posts: 72 Location: Michigan

It is a fairly straightforward procedure... disconnect everything that is attached to the head, remove the intake manifold, unbolt the downpipe from the exhaust manifold, and pull the head bolts.

Lining up the new gasket while reinstalling the head is alot easier with two people. But then you just torque the head back down and reconnect everything and youre done.
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1996 Honda del Sol Si Turbo
1977.5 Porsche 924 (for sale)

moone924 · Joined: 05 Feb 2003 Posts: 868 Location: Douglas Wyoming

I did it twice a few years ago. I had a haynes manual, and just went for it. I think I unbolted the downpipes from the exhaust manifold and pulled the head with the exhaust manifold attached, and re-installed with the exhaust manifold attached..... to make it easier
_________________
Ryan Moone

Always shopping for a nice s2 931 to baby.
New philosophy : one car project at a time.

Ozzie · Posted: Mon Jan 30, 2006 4:37 pm Post subject:

It is easier to leave the exhaust manifold on and have it on when refitting the head.
Remove it off the head after the head is off if you want.
I refitted my exhaust manifold after replacing all the studs while on the car. A real PITA.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

doomer77 · Joined: 10 Jan 2006 Posts: 266 Location: Huskvarna, Sweden

im most worried about having to flatten the top so the gasket wont blow, what kind of tools do you need to do that?
_________________
Why drink and drive when you can smoke and fly?
Carpe diem. and if that doesnt work; get drunk!

1980 924 n/a - engine swap begun
1989 Volvo 480ES

moone924 · Joined: 05 Feb 2003 Posts: 868 Location: Douglas Wyoming

there's a tightening order that keeps the gasket flat.

You should probably get a haynes manual
_________________
Ryan Moone

Always shopping for a nice s2 931 to baby.
New philosophy : one car project at a time.

doomer77 · Joined: 10 Jan 2006 Posts: 266 Location: Huskvarna, Sweden

hmm, ive got a hanyes, thanks for bringing that up
_________________
Why drink and drive when you can smoke and fly?
Carpe diem. and if that doesnt work; get drunk!

1980 924 n/a - engine swap begun
1989 Volvo 480ES

Chrenan · Joined: 15 Jan 2003 Posts: 3903 Location: Canada

Do you mean flatten the top of the engine block? The block will have to be removed from the car and taken to a machine shop to accomplish that.
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1987 951 - M193 Version for Japan

doomer77 · Joined: 10 Jan 2006 Posts: 266 Location: Huskvarna, Sweden

thats what i meant, not only flatting the gasket, but the whole top

so my question restated would be
can you flatten the top of the engine block at home and what tools do you need?

an alternative might be to buy a new top thats been pre flattened, whats the status on that?
_________________
Why drink and drive when you can smoke and fly?
Carpe diem. and if that doesnt work; get drunk!

1980 924 n/a - engine swap begun
1989 Volvo 480ES

Chrenan · Joined: 15 Jan 2003 Posts: 3903 Location: Canada

If you are worried about the top of the engine block being warped (not flat), remove the entire engine, strip it down, and bring the block to a machine shop. I'm not sure what you would need at home to do it yourself, but my guess is very few people would have the tools...
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1987 951 - M193 Version for Japan

fergie · Joined: 21 Sep 2005 Posts: 72 Location: Michigan

You shouldnt worry about the blocks straightness for the gasket to seal. It is made of cast iron, and i really doubt its going to warp before the aluminum head melts off or something.

However, using a straight edge and feeler guage, check the sealing surface on the bottom of the head to make sure it is within tolerance, as according to your haynes manual. After a certain amount of use it is likely to warp the cylinder head a little, and should be resurfaced.
_________________
1996 Honda del Sol Si Turbo
1977.5 Porsche 924 (for sale)

helowrench · Joined: 25 Nov 2004 Posts: 44 Location: Dallas

While you have the head off you miight want to replace the water hoses that are between the engine and the firewall. I do not know if they can actually be changed with the head on. I changed ALL of my hoses and had the radiator cleaned/cored/tested and changed the water pump when I did the head so I could have a little peace of mind about the cooling system.
If I remember correctly I left both the intake and exhaust manifolds on the head and removed them after the head was off.

Good luck
Rob

Dans931 · Joined: 20 Jan 2006 Posts: 45 Location: Baltimore

The N/A is alot easier to change than the turbo. Use a turbo headgasket, they are stronger. Replacing those hoses is a great idea; it is so hard to get back there. Check your exhaust manifold for cracks. All the torque specs you need will be in the Haynes. Also replace the o rings on the injectors and the timing belt. Its a good idea to have the head checked out at a shop and have valve stem seals put in.
Daniel

82 931 (8.5/1 compression)
84 Jetta Diesel (23/1 compression)

Dans931 · Joined: 20 Jan 2006 Posts: 45 Location: Baltimore

The N/A is alot easier to change than the turbo. Use a turbo headgasket, they are stronger. Replacing those hoses is a great idea; it is so hard to get back there. Check your exhaust manifold for cracks. All the torque specs you need will be in the Haynes. Also replace the o rings on the injectors and the timing belt. Its a good idea to have the head checked out at a shop and have valve stem seals put in.
Daniel

82 931 (8.5/1 compression)
84 Jetta Diesel (23/1 compression)