924Board.org

[Johnny_Haywire]

Hey guys,

Hoping to try to start my *new* 924 before winter sets in here (Chicago) and before I start ordering any parts for it. Details and pictures of the car are in my post in the "Welcome Noobs" section.

The car's been sitting for years, so my plan is to drain the fuel tank, install a new fuel filter, put some oil in the cylinders and over the cam, and then try to fire her up.

To drain the tank, is it as easy as removing the return line at the lowermost section of the tank?
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1981 924 N/A 5-speed

[emoore924]

Many many threads here regarding how to resurrect a sleeping 924. More to it than draining the tank and firing up.

That said, to answer your question, there are two ways I can think of:

1) disco the battery, remove the fuel line at the filter in the engine compartment and connect an extension. Put the end of the extension in a fuel can. Jumper the fuel relay. Recon the battery and pump the fuel out using the fuel pump.
2) Remove the "S" shaped hose from the fuel pump under the bottom of the tank. BE READY WITH A FUEL CAN AS THE FUEL WILL COME RUSHING OUT. Oh, and have a fire extinguisher handy, pin pulled.

[Johnny_Haywire]

Thanks for the tips. I've been reading up on what I've been able to find so far, and I do want to proceed cautiously.

I'm just starting it to verify whether the engine is sound before ordering parts and giving her the full going over. Much to do before she is road-worthy.

I like the idea of using the fuel pump to pump out the old fuel, but I'm hesitant to do so with any spark nearby and also hesitant to run the old fuel through the pump any more than need be.

If I disconnect the return hose instead of the "s" hose off the fuel pump, will it be pressurized?
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1981 924 N/A 5-speed

[jason c]

Pinch the line shut with pinch pliers, remove it from pump, place it in a gas can & remove the pinch pliers. You can pinch it back shut when you need to stop the flow. As Harm said, have plenty of empty cans ready.

There is no pressure, gravity will do all the work.

[Harm]

[jason c]

[Johnny_Haywire]

Thanks for the replies, guys.

So, just to make sure, pinch the "s" hose that runs from the tank to the pump, that one won't be pressurized since it's "before" the pump. Then disconnect it from the pump and get ready to start filling some fuel cans?

I don't even know how much fuel is in the tank. Hopefully not much. I'll check before I drain to make sure I have enough capacity to handle it.

I hope to drain this weekend before the temps drop really low, but probably won't attempt to fire her up for another week. Fuel filter prices from local auto parts stores are 4-5 times what rockauto charges.

I'll keep you posted on how it goes.
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1981 924 N/A 5-speed

[jason c]

[Johnny_Haywire]

Thanks for the tips, Jason. I've got some vice grips that I can wrap some thick rubber around in order to not damage the hose.

Looks like time and weather (kind of, ~50 F) is on my side tomorrow. I'll let you guys know how it goes. Clamps are soaking in penetrating oil right now.
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1981 924 N/A 5-speed

[Johnny_Haywire]

I made a little progress today, but also ended up taking a few steps back.

After preparing a safe work area with all possible causes for spark removed and with everything set for pinching the "s" hose, turns out it was hard as a rock. I removed it thinking I'd have to quickly guide it into the gas can, but...the tank was dry.

I went ahead and replaced that hose with some new fresh fuel hose and put about 1 gallon in the tank. I immediately notice a few drips starting. Turns out it was the seal at the in-tank fuel pump. Snugged that up and that leak stopped. And then there was another leak, this one from what I believe is the fuel return hose (attaches with a hose clamp to the small neck sticking out of the bottom of the fuel tank. I thought it led up to the accumulator, but after looking at a diagram, that would make no sense. This hose will need to be replaced before anything else can be done.

After taking a look around, I noticed the accumulator mounting bracket had rusted away, and is just hanging free. Put that on the parts list, as well.

I found this post, which seems super helpful regarding the disassembly. I'll start tracking down part numbers, fingers crossed they aren't too painful.

http://www.924board.org/viewtopic.php?t=15721&postdays=0&postorder=asc&start=0

Any opinions on this parts dealer (Jim Ellis)?

http://www.jimellisporscheparts.com/showAssembly.aspx?ukey_product=3644851&ukey_assembly=473825

The OEM bonded rubber mounts are kind of high there, but all parts numbers are supplied for this area.

At any rate, here are a couple of crappy pics of the state of things:

Leaky return line:


Note the accumulator hanging loose here:


Crusty fittings on the external fuel pump to accumulator line:


Hold down for the hoses is just about rusted to nothing:


More crustiness:

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1981 924 N/A 5-speed