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Project: Restoration

Contraband

PCGB Member
Member
Progress is being made. It's still not running anywhere as well as it should be but I'm getting there. Pretty sure I have a vacuum/air leak causing poor running.
In the last month or so I have got it running after 2 years in a garage, stripped and cleaned injectors, fitted a TTS bypass, fixed the rear seized brake, passed its MOT, changed the fuel filter as the old one was breaking up inside, new battery, flushed the cooling system and filled with new antifreeze and many other small jobs like wipers and perished rubber hoses.
Today I fitted a new intermediate exhaust section... Can you guess which one is the brand new £17 eBay purchase?

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I have a new strobe timing light arriving this week, hopefully that will improve the running.

I'm definitely making progress and really enjoying it.... My wife is happy for me but I'm sure she would rather I finish the decorating I started just before I picked up the 924 !!!
 
Thanks to my new timing light and my 30 year old colortune kit, the car is now running pretty well.
The car pulls in 5th gear now where before it struggled to drive in 1st. It's rubbish until it warms up but great when it's at temperature.
My son is going to use it for the next few days so I should get plenty of feedback on how it's running. New tyres next and it should be ready for the summer....

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very nice car - the 924 2.0 had a cold start valve - replacing might help the cold running - I cant remember fully I think I paid about £40 for a new one 12 years ago ....... might help -
 
^ Thanks... You are right. The thermo time switch is faulty. It's not allowing the cold start valve to stay on long enough. I have fitted a bypass switch as a temp fix. It starts better, but we don't drive it until the temperature dial has moved up a bit, then I find it runs ok.
 
Here is a video my youngest made of our road trip to an open day event. My sons are in the 924, myself in the Cayman.
The 924 looked excellent parked next to the supercars and had many compliments.

http://www.youtube.com/watch?v=uwnWi8Pg5pM&feature=youtube_gdata_player
 
The cold start valve which is the sort of fifth injector should only open for between 4 and 15 secs approximately so effectively should have little or no influence on cold performance of the engine. Do the obvious first, remove the banjo shaped rubber duct and check that the metering plate is corerctly centred in the plenum chamber. If it drags then the richness of the mixture will be affected. If it needs re-centring this is easily done with a .004" feeler gauge tested at three points around the plate. Failing this then I am inclined to think that you have a problem with the warm up regulator, aka control pressure regulator. What this this seemingly inert block of aluminium on the inlet manifold (iirc) is supposed to do is lower the control pressure in the metering unit. The control pressure controls how much the air-flow plate deflects for a given flow rate, so for example when the engine is cold the arm will move further up to reach the stable position in the airstream for a given airflow, which in turn moves the metering spool further up, opening up more of the metering port to fuel flow, long story short acting like an automatic choke. Inside the control pressure regulator is nothing more than the open ends of the feed pipe from the top of the metering head and the return to tank pipe (whch may or may not "t" into the main return pipe I can't remember) and a heated bimetalic strip with a seal on it that when cold bends back and allows the two pipes to interconnect, reducing the pressure on one side of the stainless steel diaphraghm in the metering head. This is what allows the round air-flow plate to deflect more, richening the mixture, when cold. As the metalic strip heats up, (electrically and via heat soak) the inter-connection between to two pipes gradually reduces until, once at the corect operating temperature, the two ends of the pipe are sealed from each other and the increase in control pressure pushes back against the forece of the metering plate more and leans the mixture out. A control pressure regulator will be considerably more than £40 probably by an order of magnitude. It would certainly be worth, in this day and age, and the vintage of the design, taking off the cpr and taking it apart to see if the strip is opening up properly. Conversely the rubber seal may have deteriorated giving false richness, which someone may have attempted to compensate for by leaning off the mixture via the adjusting screw on the metering head. I say this so that if you find the internal seal is useless and repair it even temporarily you may have to tinker with the mixture via the screw to rectify the rectification if you see what I mean. You might want to smarten up your by-pass into something more permanent because the 2.0 engine is infamous for its warm start problems, caused by a vapour lock. This happens when the check valve on the end of the fuel pump lets by. For brief stops the fuel accumulator will maintain pressure but will not keep the pressure up for more than a few minutes. I know this from experience with a jury rigged earth bypass for the cold start valve which I used to use to start the car when it was warm. The fuel pump relay has a safety circuit in it so it will not run until the it either has the earth return on the metering body broken by the plate lifting on early models, or by the fuel pump relay getting pulses from terminal one on the coil on later models, so at 10v (starter engaged) the fuel pump has what is known as "bu99er all chance" of pressurising the fuel lines. Then the fuel pump packed up and the only connection I could undo was the check-valve to pipe connection so when new pump was fitted complete with new check-valve the warm start problem dissapeared.
 
Hi John.. All good info. I have already stripped and cleaned my WUR. I am convinced the diaphragm is faulty and not lowering the pressure to allow the plate to move more freely when cold. The TTS is duff. It only allows the CSV to spray for 1 second max. I checked it with a light bulb. Without the bypass it's impossible to keep it running long enough to get enough vacuum to lift the plate and switch injectors on. I'll keep my eyes open for another WUR. It's a great starter when warm/hot.
 
The tts may not necessarily be duff. From 1987 to 2003 I never had a tts fail in my 2.0 but that's not to say that they never fail. TTS function is based on ambient water temperature as well as time (you probably already know that) so if it's giving a 1 second burst that could be all that is required. Have you considered assmbling the WUR without the diaphragm in some way so that the two pipe orifices are permanently open, to prove a point. If it starts and runs initially with a tendency to richen up as the engine warms then this would be a good indication as to whether the WUR is working.
 
Based on the assumption that your hard wired bypass works fine, can I infer that when you did the test with a lamp, you put 12v directly to the lamp and earthed it throughthe tts?
 
That is a good idea about the WUR. I think I'll try that....

I unplugged the CSV and pushed the wires from my bulb into the plug. As you say, the circuit is completed via the TTS.

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ORIGINAL: Contraband

................. Without the bypass it's impossible to keep it running long enough to get enough vacuum to lift the plate and switch injectors on................ It's a great starter when warm/hot.
Even at cranking rpm there should be sufficient "vacuum" or airflow past the plate to lift it from its seat and "turn on" the fuel supply. The pump then has to supply the injectors with fuel at more than 3 bar to open the check valve in the injector at a flow rate determined by the stable position of the plate in the airstream. If you think that you are not getting enough "draw" the check the ducting for leaks. There are two stubs on the rubber banjo, from memory, and I have had one of these split drawing in air the wrong side of the pplate. Also the straight plastic slightly tapered duct can collapse if the jubilee clip is tightened tooo tightly and the orifice will assume a vestigal figure of 8 shape with leaks in the obvious place around the waisted section of the "8". Probaly all red herrings becuase you say that it is a good warm starter and runs fine when it has warmed up
 
Just to be picky in your description you mention 19 inch turbo wheels. That must be a typo. Stricly speaking the Turbo wheel will not fit a 924 unles it has the m474 handling pack which includes 5 stud hubs, and the dog-leg gear box, which yours does not have because you have the four stud wheels on in the picture. Nice condition by the way. You could have by now fitted what is known in the U K as the Le Mans wheels which greatly resemble the Turbo wheel except for the black side to the spokes. In the US where the 924 t only had 145 bhp Porsche did not see the need to fit the ventilated discs all round so stuck with the disc/drum set up as per the 2.0 so by the merest tenuous conection you could say it had turbo wheels. These wheels to my knowledge (which is not definitive by any means) were only available in 15 inch diameter.
 
Lol... I wish 19" on the 924. The 19" wheels are on my Cayman.

There should be enough draw at cranking speeds, but if my WUR is faulty it will not drop the fuel pressure enough to allow the plate to move a bit easier at cranking speeds.
Yes, air/vacuum leaks. I have even smoke tested the joints and can see no evidence of leaks.
My initial thought was that it must be a vacuum leak, but I have not found one. I still think its my WUR that is at fault. I am going to try your suggestion of maybe removing the diaphragm to prove a point.


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So today I had the longest run in the car yet. I did just over 100 miles on a run along the A924.

I now know what is needing done next.
I need new tyres. There is a speed vibration that starts at about 55 and stops at 70. I knew I needed tyres but today has proved I need them now!
There is still a misfire. I am going to buy new HT leads.
I noticed a bit of pinking on hard acceleration. I set the timing using 99ron tesco fuel. It now has a tank of shell 95. That might explain it.
I'll either redo timing or just give the mixture screw a bit of a turn..
The brakes need doing. They are squealing a bit, front and back. They work well when you press hard, but they are not up to the standard I want.
The exhaust manifold gaskets need changed... I hope it's easy enough to do without engine removal...
That should be enough to be getting on with just now....
 
That's the tyres changed on the front. I fitted continental Eco 5's and what a difference. The speed vibration is gone and it appears to turn easier at low speeds. As the car had stood still on the tyres for 2 years they were probably flat spotted.
The date stamps date the tyres from '92 and '93. They still had loads of tread on them as well !
I fixed the pinking by turning the mixture screw 1/8th of a turn to the right to richer the mixture a tad.
 
ORIGINAL: Contraband
The exhaust manifold gaskets need changed... I hope it's easy enough to do without engine removal...

Yes it is possible. When I did it none of the studs sheared (surprising) and I refitted the manifold with all new gaskets, nuts and studs.
If you did get a stud shear, I don't think you've room for an extractor without taking the head off/removing the engine.
There is not much room to work anyway and the heat shields can be very difficult to remove.
Can't remember if I removed the double UJ steering shaft or the starter motor for better access.
It was a combination of working from above or below depending where you were on the manifold.

ORIGINAL: Contraband

That's the tyres changed on the front. I fitted continental Eco 5's and what a difference. The speed vibration is gone and it appears to turn easier at low speeds. As the car had stood still on the tyres for 2 years they were probably flat spotted.
The date stamps date the tyres from '92 and '93. They still had loads of tread on them as well !

Been there as well, what happens is the sidewalls tend to sag after 5 or so years so you end up with more rubber in contact with the road than the steering was designed for and it feels very heavy at parking speeds - grips well at speed round bends though . . .
 
I have just ordered another 2 tyres for the rear. I went onto a roundabout recently and decided to test the grip levels of the new front tyres.... they performed flawlessly. Unfortunately the rear of the 924 decided to try and overtake me. It actually must have looked pretty good to any onlookers because it was a pretty perfect slide, but as it was unintentional the tyres are getting binned.

I went into the garage and found a pool of water under the engine. I traced it back up to the thermostat housing, it was leaking around the join. It was easy to remove with only two bolts to take out and perfect access being at the top front of the block. A quick clean up of the surfaces and a coating of blue instant gasket around the faces and old rubber sealing gasket has cured the fault. Luckily it is such an easy car to bleed the cooling system.

The plan is to change the gearbox oil this weekend.....
 

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