My Porsche 964 C2 diary

[MarkGolf]

Update, not too much has been going on with the car since winter and more lockdowns kicked in..

I did have an issue where I broke down on a busy bypass, this was down to a voltage regulator with sticky brushes.

So I replaced the dodgy VR with a new BERU one, a really simple job to do.

Pull this forwards

Remove a cover, 2 screws to remove old one and put new one in, simple.

As the car is getting on, some of the bushes have been changed to an unknown brand of Polyurathane and OEM by a previous owner, I wanted to just refresh EVERYTHING. So I went for the full Powerflex kit, wishbones, gearbox and ARB bushes. I chose the new Heritage range of bushes, these are not as firm as the usual yellow, purple and black bushes that Powerflex are known for. These are grey, which indicate that they are the Heritage range and with that, not hard but OEM in feel, if ever so slightly firmer but won't degrade like rubber bushes, so will outlast them and keep motoring for many more years to come without lose in performance.

Changing bushes is the worst job for me, it is just one of those pains, I will be investing in a press to make it much easier and then it may not be a job I put off in future. The results are always the most satisfying however, that's the drive I need to remind myself so that I get on and get it all fitted.

I got myself some later spec 4 pot rear calipers to upgrade my baby 2 pots, I will be stripping and rebuilding, new piston and dust seals anyway. New finish, decal and stainless nipples.

I got to work on fitting the gearbox mount bushes.

Just fitting the gearbox bushes alone has made a noticeable difference, the car generally feels more solid and the pickup when initially setting off is like a sport mode button has been enabled, it is a night and day difference and for the effort and cost, hugely worthwhile doing! I fitted the insert kit which fills the voids around the existing bushing, I went for this option rather than full bush replacement for ease, I don't regret it as the improvement is superb. I went for the void filler bushes on another car of mine which had good results (mx5 differential mounts), no disappointment here with the 964!

Finally, I was getting a bit fed up with my car cover leaving light marks, dust getting under it and coming to the car during these cold months to find a hazey finish on the paint and windows and even my gauges, where condensation had clearly got to it.
I bought a car bubble from ebay (www.carbubble.uk) £385 or so and now, the car will stay immaculate and save me the annoynce of marking the car and condensation damage! My Golf sits in a Carcoon in a damp garage and it has remained perfect so I know the benefits of these chambers. Well worth a purchase!

Next are these 2 big boxes

 

[mcgc0]

All looking good. Keep it coming Mark. Have my Beru VR here but yet to fit (means heating up the garage - flippin cold). Didn't know about the grey 'Heritage' range from Powerflex. However, mine all done a few years back using the SuperPro bushes. Chris at Centre Gravity did them all and made a massive, more confident, difference.

 

[colin129]

I was thinking of getting some of those 4 pots for the rear brakes, how do they feel in comparison to the 2 pots?

It's really annoying, as reported here previously, that my rear brakes have always been fine, but after a recent pad change, now they squeal all the time. Try fitting 4 pots, said the garage [8|][&:]

 

[mcgc0]

What new pads Colin? Garage talking a bit of tosh if the answer was to replace the calipers. Pad material change should fix that (plus new anti-squeal shims).

 

[colin129]

What new pads Colin? Garage talking a bit of tosh if the answer was to replace the calipers. Pad material change should fix that (plus new anti-squeal shims).

Well you would have thought so. They (should) always fit OEM parts and I've never had a brake squealing problem before. It's a well known, and respected, garage, but since the last of the original owners left, It's not quite the same. My bodywork guy, who has his workshop round the corner and who they originally recommended to me, no longer works with them. Also, after my last service, the receptionist got the right hump (silent treatment) because I was 5 or so litres short refilling the loan car, whilst I was paying my 4 figure bill!

I think our long association (20 years) may be over and I may try the people you use. I heard several of the staff have moved over to them anyway []

 

[mcgc0]

Problem I've got now with them is their labour rates are now £98/hr - creeping close to London OPC rates. Thing is it's slowly becoming more of a GT3/2RS and 991/2 RS performance parts resellers. Clearly I guess that's where the money is and not with the likes of me - diy'ers who occasionally use them for more specialist repairs or maintenance. 10 hours of labour pays for the new garage lift I have.

 

[colin129]

My guys are heavily into the GT3 scene too, as well as very expensive used cars.

I'm not sure what their current labour rate is, tbh, virtually everything they do for me is menu priced, but it can't be far off that (£80/85 + VAT). Still, I think you are looking getting on for double that at an OPC.

 

[gordonparker]

Many thanks for an interesting and detailed article, most long term 964 owners can relate to the issues and challenges that come with a car of this age[]
Look forward to reading the next challenges

 

[MarkGolf]

Thanks!

I hope that's all for now, saying that, I have noticed a PAS fluid drip which goes down onto the heat exchanger, seems to be dripping from a purpose made hole up in the bay, when looking up from below. Need to investigate that at some point.

Not much to report, having trouble finding the time for anything between work, family, new house and 7 other cars!

Got boxes of new parts and more coming, just need time.

Finished my 4 pot rear calipers, happy with how they have come out. New seals, stainless nips, new decal under the lacquer.

I had a photoshoot with Classic Cars magazine and that's out this month.

Got lots of great photos which was nice.

As she stands, I am planning on fitting my EBC brake kit this weekend along with the calipers, rest of the powerflex kit has to go on to.

 

[MarkGolf]

Made a start on the brakes, started from the rear and just didn't get anywhere near the amount done that I had planned, a few hurdles and visitors slowing my progress though.
I went in blind and first issue was access to the lower caliper bolt, I didn't have an extended allen socket (on order now), I ended up using a small version with a spanner but wasn't ideal as I ended up winding it out too far and got the bolt/tool stuck! Fortunately, lots of wiggling and a magnet saved the day, eventually!
Pretty dirty under here at the moment but smaller early spec 2 pot caliper due to come off and disc, plenty of meat left on the disc but it is old and has some grooves, pitting and rust.

Disc and caliper off, shoes look fine, annoyingly, I have brand new shoes but they were in my other garage and I didn't want to stop my flow, so I decided to not change.

EBC discs to replace the originals. I know the Porsche thing is to have primer finished centres but they just show the dirt and eventually look bad when the coating wears, I like the black finish on the EBC's, will keep things looking neat when looking through the wheels.

Caliper mounted and EBC yellow stuff pad, original wear sensors slotted right in along with brake line, very easy conversion and if the caliper has to come off to change the disc anyway, why not change it.

Comparison

I went on to replace the rear rubber brake line but found someone had rounded the inner union, so I just couldn't get a grip on it, I have some better mole grips so will try with those but was an awkward position along with brake fluid dripping down my arm, I gave up and decided to try again another day. The rubber hoses look tired so I need to replace them with the nice braided versions I have got.
Slow progress day, they happen. I had hoped to get all 4 corner done!
Next update will be the complete job done.

 

[mcgc0]

Looking good Mark. Brake repairs/replacements have never been straightforward for me - you start well and think you're on a winner then a completely seized bolt ruins your day and you end up having to do workarounds. Did you say you were going to replace the callipers up front too?

 

[SteveF]

Nice read Mark, just stubbled across this and read it from start to finish, realised halfway through that I follow you on Insta!
Nice to see the D90s and flags.
Steve

 

[MarkGolf]

I have always hated doing brakes, just a messy job and when it goes wrong, it's normally a nightmare. Bleed nips that shear off, rounded unions and just general mess. I've got the kit to remake brake lines but that would just be a hassle I could do without.

Not replacing the fronts, will inspect the dust seals and will replace if need be. Will change the bleed nipples to stainless ones and then just fit new EBC discs, yellow stuff pads and braided lines.

Thanks Steve, had to be retained, always been on the fence and close to changing but I want to retain the original look of the car, just improve it under the skin. It's rare to find a 964 on D90's and flags.

 

[colin129]

I have always hated doing brakes, just a messy job and when it goes wrong, it's normally a nightmare. Bleed nips that shear off, rounded unions and just general mess. I've got the kit to remake brake lines but that would just be a hassle I could do without.

Not replacing the fronts, will inspect the dust seals and will replace if need be. Will change the bleed nipples to stainless ones and then just fit new EBC discs, yellow stuff pads and braided lines.

Thanks Steve, had to be retained, always been on the fence and close to changing but I want to retain the original look of the car, just improve it under the skin. It's rare to find a 964 on D90's and flags.

Join the club []

Very interesting. I used to do a lot of work on my car, but, one cold November morning, lying in a puddle trying to wrestle new shock absorbers onto a Dolomite Sprint finally made me realise I like driving, not getting cold wet & dirty. I brought a Mk2 Golf GTi, that never broke down, and never looked back.

 

[MarkGolf]

Oh tell me about it, before my garages I was always outside, rain or shy, if a job had to be done, I would just do it regardless. I actually fitted an engine into my Golf during snow! That was interesting. I was younger then, now that I'm getting to the middle ages and life is taking my time, I do find myself contemplating paying someone to do the work, I just like getting my hands dirty!

Has anyone had any experience of front strut braces? I was doing some research and found some forum posts about an increase in steering feel. I do find that mine is lacking, possibly due to the big balloon tyres and OEM bushes, powerflex's are lined up to go on shortly but while I am looking to tighten the car, I was considering a strut brace to try and hide behind the carpet...

 

[mcgc0]

Has anyone had any experience of front strut braces? I was doing some research and found some forum posts about an increase in steering feel. I do find that mine is lacking, possibly due to the big balloon tyres and OEM bushes, powerflex's are lined up to go on shortly but while I am looking to tighten the car, I was considering a strut brace to try and hide behind the carpet...

I have a carbon fibre one fitted to my C4. Tbh, whether it makes a difference or not I couldn't tell - could be with the 4-wheel drive I'm going to get a slightly different steering feel than a C2, who knows. I strongly suspect that if you're a trackday banana then yes, it would make a difference with small strut 'lean' being eliminated. I thrashed my C4 for 4 days continuously a few years back on a 700 mile Highlands jaunt with a few friends. Car felt planted - front and rear. Without a strut brace then maybe (if anything) it would have been different.

Decent bushes going to make the bigger difference. I went the SuperPro (Australian) route and glad I did. I've heard great things about them. They don't have the range that Powerflex do but I hear many pro driver/racers opt for SuperPro as a no brainer. I can't comment on Powerflex but apparently Superpro has the correct equipment/technology to bond polyurethane and metal (bushes with metal casing - close to many originals) whereas Powerflex did not at the time - 10 years back. Superpro supply their own grease with their kits which in conjunction with a cross hatching on the bushes where the bush meets the chassis or whichever car part. So holds the grease better, therefor not having issues with squeaking which some have had with Powerflex - can be annoying but does not affect performance (Powerflex supply copper grease with their bushes). However, want to make clear I'm not in any way suggesting Powerflex aren't as good of course - each to their own.

 

[air-cooled-fan]

Agree Colin. My moment of epiphany was replacing a mini clutch on a very wet winter's day with the car parked in a gutter on the side of the Finchley Road in London. Got sprayed every time a bus came past!
Never, ever again... leave it to the experts.

 

[MarkGolf]

Brake job complete, finally.
Fronts were pretty straight forward until it came to replacing one of the bleed nipples with a stainless version, I ended up fitting it on the piss and completely threading the caliper! Rather than repair, I bought a pair of replacement calipers to rebuild and fit to replace both fronts. Quite annoying but I like to change brakes in pairs and rather than take a chance on a re-thread, I'd rather have a factory job.
Original disc and pads with what was to go on, EBC disc and Yellowstuff pads.

New bits on, just after the thread strip! Doh.

Caliper had to come off, annoyingly I could not undo the copper line that joins to the caliper, not such a problem as someone had remade the line and I wasn't too happy with the job, so it gave me a opportunity to rectify this.

New pipe made. I really want to replace all of the copper lines but that's a job for a winter.

Braided lines to replace the original rubber versions

Expected aggravation

some new ones of these

Replacement and rebuilt, refreshed caliper, ready for another 30 years, or until Singer buy the car and bin it.

Back on it's wheels and ready to test!

All because I wanted to see a 4 pot through the spokes.

Well, the brakes need bedding in properly this didn't happen, however, the pedal already feel much more solid, it was pretty spongey before but now the brakes feel sharp and it wants to stop. Looking forward to properly bedding these in to see how they do. Anyway, I had to cut my bedding in short as a misfire has reappeared. I had one a while back which led me to rebuild the dizzy system, well, the only parts I haven't changed are the coils and the leads. So I thought I would change the coils.
So coils have now been replaced.

However, it seems the car doesn't want to fire up without throttle. I have always been able to just reach in and turn the car on. Once it has been started, it can sometimes be started without throttle, it's a bit hit or miss.. Need to investigate that but as a start. I'm told it probably needs an adaptation with the hammer tool.. The revs seems to fluctuate as you'll hear in the youtube vid below,
https://youtu.be/spbFu9f2XXc
Points to anyone who knows what that plug is between the coils

That's it for now! Hoping I can easily solve the running/starting issue, it probably just needs some fresh fuel and a good run!

 

[MarkGolf]

Well, had some excitement here but not the kind I like, it seems the chasing of the misfire I had been doing above, was in the wrong direction and I found out the hard way.

I was readying the 964, for a run to the Fairmile meet, started with a minor issue which resulting in me spotting that the MAF had come loose. Refitted that and all was well, a short drive and the misfire was back, this time, NO power whatsoever, then a BANG and lots of smoke!

Pulled over, which happened to be in the EXACT spot I broke down last time and open the decklid to clouds of smoke but no flame (that I could see) but smoke was coming out from places I couldn't see. Tried starting the car to see if I could see anything going on, the car started but cut out instantly followed by lots of smoke, I ran round the back to see fire, fortunately, I was able to blow it out.
The same bloody spot I broke down in last time

Evidence of fire..

Deformed lower intake joiner

Recovery arrived and the next issue was that the tow eye which came with my car, wasn't the right one and the guy didn't want to pull the car by a wishbone, so we had to get some helpful people to help push (no one around) or start it. I said no, no way we can start it as it caught fire the last time, so what did we do, started it again and yep, fires back. At least this time, I got to see exactly where it was coming from and spotted fuel leaking out of the lower intake manifold! (WHAT!!) Blew it out again and said, that's why I wasn't keen.
Anyway, we found a helpful chap who helped us get it up the ramp easily enough.

Back in the garage, totally confused as to what was wrong, I had pretty much decided on sending it in to someone to sort, I was done and pretty short on time to be messing around problem solving at the moment.

Then, I got a message on instagram with a story from someone who had the same thing, fuel pressure regulator!! It made instant sense, that's how the fuel is getting up there. The diaphragm in the FPR becomes weak and with the vaccuum pressure, fuel is sucked into the manifold which then causes bad running, also, fuel pressure is not held which results in longer cranking times.

So, now I had a lead, I could set about on a resolution.

I found an OEM FPR to be too expensive for what is is, so I looked into alternatives and of course, found some innovative ideas from guys in the US. I was put onto 928sRUS. They supply billet FPR housings which hold a generic regulator. Great idea, if it ever fails again or anyone wants to upgrade it, it will be cheap and easy. So I bought it! $250 + shipping, I think the total was £209. Great

While I awaited the arrival of the FPR, I set to work on the strip down and to access the damage. This is the first time I have removed the intake and was looking forward to it, all straight forward, just so many damn pipes!!

I plan on attempting to tidy this lot up, what a mess!

Inside intake, can see where fuel had pooled up.

All apart and the only damage was the 2 rubber joiners on the drivers side, between the TB and cast intake, phew!! While in there, I have been able to clean a few bits up, found that the jubilee on the oil breather was completely loose, resulting in oil residue around the local area.
One of the fuel hoses was a pain to undo while in the car, so I ended up undoing it from the fuel rail side and then undoing it from the FPR in a bench vice.

A loose jubilee resulted in some oil weeping

While going this far, I removed the injector, noticed that some of the caps were melted, so I have sent those off to Injector Tune for a full refurb and while the fuel hoses seem perfectly fine, no cracked, bendy, no issues, I am going to pop into a local hoses specialist to see if they can supply the correct hose and re-crimp them onto the OEM end fittings. This should be straight forward and avoid the heavy costs of brand new parts from Porsche.

https://www.injectortune....Cleaning_Services.html

Also, I am going to rebuild the PAS pump as I do have a leak which then drops onto a heat exchanger, resulting in a bit of a smoke show.

So all in all, I got VERY lucky and once back together, it will be a better car

New FPR just arrived, literally just under 1 week from my order, all the way from Texas! I'll be heading to Porsche Brooklands tomorrow morning to collect a bunch of new parts, clips, rubber joiners, fuel filter, oil filter, heater pipe resistor (thats another thing which causes fires) and few odd bits. I hope to get the fuel lines done too if my local Pirtek will do them, so as soon as my injectors arrive back, I can get it all buttoned up.

Old resistor but has the later part number, so not all bad, just old and worth renewing as it looks a bit crusty.

PLEASE PLEASE PLEASE!!!! Check your FPR's, if they are original, just change it! It's not worth the potential problem you may have. I had starting issues, fluctuating idle speed and misfire when under load, all out of nowhere really. I expect my starting and running to be perfect once back together.

A quick test, pull the vacuum line, see if it has fuel in it, some guys have pulled them to find fuel spills out. If you have starting issues, it could be a sign of a failing FPR.

Part 17 here

More to come soon!

No affiliation with the companies mentioned, just random guys I decided to use after doing some basic research and getting some good feedback on them.

As she sits, degreased, and cleaned as much as I can do for now.

 

[Stephenjk]

Thanks mark for an excellent write-up! Good tip on the FPR I'll be looking at mine at the weekend. On the fuel in the vacuum hose do you know if that is only after a long run or will starting it up and then checking, be enough?

This is the part I believe Mark is referring to as a potential replacement https://928srus.com/products/928-110-198-25am-billet-fuel-pressure-regulator-88-to-95?_pos=13&_sid=a10d40a6c&_ss=r

Stephen