924Board.org

[JayZzzz4]

NOW THAT it's SUMMER, MY car wants to be lazy and sit around and Take baths once a week and a Wax ever month! I DOnn't think sooo... I didn't buy a Porsche to just sit around....

Ok NOW the bad news....
Well about a two week ago I found some coolant sitting on top of the engine block where inlet one is bolted, I looked around and didn’t see anything. I thought I might have over heated the engine. I cleaned it up and it went away till today.

Here the story: I’m working on my heating problem still, I put a new radiator switch in last week and the fan still won’t turn on. I know if I touch the wires the fan works, so I thought my switch isn’t getting hot enough because there might be air in the radiator from when I put the new switch in. I know I lost a lot of coolant and it looked like a lot of air got in. So when I was done with the switch, I ran the engine and a lot of air pocks came out into the coolant tank. So after looking at it and trying to find the problem, I thought, well what if I loosened up the hose from the radiator to the engine to see if my coolant tank would go down. My engine was hot from just driving it for 10min and as I put my hand on the hose with a little pressure on the coolant inlet on the engine, I saw coolant leaking out of where the inlet and block meet. I stopped right away and notice that one of the bolts was very loose, I trying a few turns and it wouldn’t go in. I took it out and saw that the treads where really bad and so I put a new one in and found that it stopped in the same place. I looked at the other bolt and saw it was loose too and found out quick it had the same problem; they keep on turning but won’t go in. By this time coolant was leaking all over the place. It looks like the PO ran into this problem and used some kind of sealer to hold it in place instead of the bolts doing the job and over 800 mile it worked till now. I’ll have to take the inlet off to see if the treads are any good or not, something tells me they aren’t. On the positive note, my engine didn’t warp from over heating and this should solve my heating problem.


Any ideas what to do or where to go from here? Can I just re-tap them and if I can’t use the same size go bigger or do I need to buy a whole new head or something crazy and expensive? I’ll be buying a gasket for sure for the inlet.
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White 1987 Porsche 924S manual

[Smoothie]

Thread repair options - http://www.924board.org/viewtopic.php?t=26694
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"..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

[Paul]

Which ever way you decide to repair the threads, I'd use studs and nuts instead of new bolts.

BTW the other hex head is the bleeder screw that should have been out when you refilled the cooling system.
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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.

[JayZzzz4]

Just an update, I drilled out the glue using a 5/16" bit and I found out why they used glue in the first place.There is a rubber part attached under one of the holes and is leaking coolant around it now that I drilled it. I think I'm going to use JB weld to seal the bottom of the hole and put some Threaded Inserts in. I tried tapping it with a 3/8" tap and I gave up because I don't have the right tools, I need an extension so the tap has room to spin without hitting the intake manifold or the cam housing.

Here's my inserts I'm ordering:
It's the 1/4" 20 inside tread with an 3/8" OD tread.

http://www.mcmaster.com/#threaded-inserts/=22sjb8
(Link doesn't take you to the right place, Go under "Self-Tapping" and then under "Self-Tapping with Circular Cutting Elements")

My only question is: Is there any where else cheaper then Paragon Products to order a Gasket for the Water Hose Flange. It's only $9, but there's a flat rate shipping of $8 and I just ordered all my parts a needed about a mouth ago so I don't need anything else. I know that it's nothing and I'll just have to get it but thought I would ask.
http://www.paragon-products.com/product_p/pp-944.104.311.06.htm

Also let me know if I'm not going about this the right way
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White 1987 Porsche 924S manual

[Paul]

Did you call Concours for a price?
_________________
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.

[JayZzzz4]

No I didn't... I thought they would sell it over priced. Mmm I'm in Chicago now, there are Porsche dealers everywhere, I think one in about 4 miles away and I should stop in and see it



hole on the right side is the problem
_________________
White 1987 Porsche 924S manual

[Paul]

Some times Concours will try to match pricing.....
_________________
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.

[Smoothie]

I'm not personally familiar with the 924S engine and that specific threaded opening,
but many engines require some silicone sealer on certain bolts that enter water passages
(sometimes a head bolt, waterpump bolt/s, thermostat housing bolt/s, etc.). -So maybe
that one needs some sealer - that might account for the rubber you're finding there.
-But wait around for an answer from someone who knows for sure..

I would do the thread repair in the appropriate metric size rather than switching to
an inch size. -And get a sheet of gasket material from the local auto parts store and cut
my own gasket.
_________________
"..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

[JayZzzz4]

Update: I used one of the treaded inserts ¼-20 ID, 3/8 OD and had the hardest time getting it started. I drilled the hole to right size for the treads to dig it. I guess now that I look back at the whole project, I should have gone to the store and buy the next size bit and try again. I final got it started and then it stopped about 1/3 of the way in. I was using a ¼-20 bolt with two nuts on the end to keep it from spinning inside the insert. Long storey short, I broke 4 bolts trying to get it to go down. (there’s no way to back the insert out unless you had a bolt with a tread going the other way) My final try, I filled the bolt up with nuts 5-6 of them, tighten them down to each other and turned them so they were all lined up for a socket head to fit on all of them. It started turning and the pop!, the insert cracked off. Luckily it broke in such a way I could pull it all out. I decided that I would use studs and JB-Weld them in. So I drilled the holes to 3/8 in the head and cut two 3/8 bolt heads off.

Paul, I should have done what you said right away and save me about 1.5 months of time.
As of yesterday, it is all finished. All I need to do it jack the front up (or a hill) and get the air out of the block and put coolant in. I hope to get it driving this week if I have any time between 6 credits of summer classes, part time job and summer yard work on 5 acres of land on a lake with two ponds (more work than it is fun).



I'll find out if JB-Weld is any good...
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White 1987 Porsche 924S manual

[Paul]

No need to jack up the front of the car, just park it on level ground and follow the bleeding procedure.
_________________
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.

[derg]

We use JB weld a lot...as long as you clean off the area with brake cleaner the stuff works well.
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"there are more stars in the sky than grains of sand on this planet"