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Wayne 962's Avatar
Wed Progress on Project 959... (10-24)

I spent a bit of time with the car today. First, I buttoned back up the air filter, and all of the remaining hose connections so that we could take it for a drive. Well, the oil switch replacement was a success, but unfortunately, that apparently wasn't the problem. The oil pressure gauge is reading very erratic - sometimes it pegs and sometimes it gets "stuck" at level 2, and sometimes it reads normal. This is troubling, because the problem could be with the gauge, or it could be some type of oil pressure problem with the engine. I tend to think it's the oil pressure sender, as these things fail all the time (like the switch). I ordered a new one and may install it in the near future.

I also am thinking that the car hasn't been driven too much, and the oil pressure sender is a mechanical device that may be sticking. Towards the end of the drive today, it was registering more reasonable values. Trouble is, the oil pressure relief pistons can also stick. Although this is highly unlikely, too much or too little oil pressure can be bad for the engine. Either way, I need to keep a very, very close eye on this, and see if the gauge keeps reading the proper values (like it was towards the end of the drive today).

Good news - I performed the test of the first turbo today using the in-dash boost gauge. Although this gauge is not very accurate, it's accurate enough to tell me if the boost is stuck at 1.5 absolute or not. The good news is that the gauge read past the 1.5 when running the test. The test says to drive the car in 3rd gear at 3000 rpm and simultaneously press the brake and then press the accelerator all the way down to the floor, maintaining full load, full throttle, and 3000 rpm. It says to do this for no more than 3-5 seconds of course. Well, the boost gauge measured levels above 1.5, which leads me to believe that the loose hose problem (shown in an earlier thread) may have been the problem with the system (what an easy fix that would be if that indeed was the problem). Again, it seems as if previous attempts to maintain the car were less than adequate.

Last week, I also reset all of the codes for the drive control system (there were about 20 fault codes stored). Well, we drove the car for about 30-40 minutes today, and the annoying drive control alarm didn't come on. In what could also have been the world's 2nd easiest fix (next to the loose hose in the turbo system), clearing out the codes and reseting the system (using the 959 code reader that the previous owner didn't have) may have solved the problem. We'll have to monitor that closely, but indeed I was surprised that the drive control error did not come up while driving today (as it had on almost all other drives over about 20 minutes long).

I would love to take this thing home and test it on the roads around Palos Verdes, but with the wildfires, I don't want to keep it outside (Boxster project car is filling up the garage these days). PV is a good driving ground for the car, as there are wide open roads, no one around at night, and no houses near the main road so you won't disturb anyone with "the noise."

One BIG problem remains - the climate control system. Today, it thought that we were driving in the Swiss Alps, and adjusted the temperature accordingly. Seriously, I thought that the wildfires had come home - the vents were outputing 100% of the hot air from the engine into the passenger compartment. As you can imagine, that's not pleasant. There seems to be 4 or 5 different temperature sensors that control the system - I suspect that at least one of them is dead or malfunctioning. The factory manual has a bunch of pages on what the resistance values should be as the car heats and cools - we'll have to go through those one by one. Trouble is, you have to pull out the radio to get to the AC / Heat control unit, but I don't have the radio removal tool. Perhaps I'll post a pic and see if anyone has one for this radio.

I also bought the 959Registry.org domain, and will archive all of the information that I find out on this wonderful car on that site. If you go there, I only have a temporary parking page for the moment (www.959registry.org).

I forgot my camera today, so I don't have any pictures. But in lieu of that, I scanned my newly arrived English language 959 brochure, and I will post it here. This brochure is perhaps one of the best documents I have ever seen that clearly and concisely explains all of what the 959 is about and it's unique features. Very cool:






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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
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101 Projects for Your MINI Cooper
Old 10-24-2007, 11:08 PM
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I got my RS rear bumper mounted this week:golfclap:

Small potatoes in contrast to what you have going on Wayne. I'm fascinated by the amount of technology that Porsche put into that car.

Keep going!
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Old 10-24-2007, 11:37 PM
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Hey Wayne, I had a similar problem with the climate control in my Mercedes recently. I suspected a faulty sensor as well, but it turned out to just be a blown fuse. I know the 959 is not my Mercedes, but it might be worth checking the fuses before you pull the radio.
Old 10-24-2007, 11:58 PM
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Quote:
Originally Posted by Wayne at Pelican Parts View Post
Here's a photo from the manual of the radio removal tool I need:



Looks like I found it right here:

http://www.midwestelectronics.com/blaupunkt-radio-removal-tool-8601910002-p-147.html

or part of this kit:

http://www.amazon.com/Astro-Pneumatic-18-Piece-Radio-Removal/dp/B000IOAX00

Anyone have one in the local area? I may actually have one somewhere in my toolbox, but I don't remember...

-Wayne
Looks like you could use some tig rod or regular coathangers and bend your own
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78 911SC SC to 73RS imposter SCWDP crew #50 and 51
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Old 10-25-2007, 12:23 AM
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Funny how that brochure makes me feel like a six year old in a candy store.
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Old 10-25-2007, 12:45 AM
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Wayne 962's Avatar
Quote:
Originally Posted by rdrr View Post
Hey Wayne, I had a similar problem with the climate control in my Mercedes recently. I suspected a faulty sensor as well, but it turned out to just be a blown fuse. I know the 959 is not my Mercedes, but it might be worth checking the fuses before you pull the radio.
That's good advice, I'll check them tomorrow, although the A/C did work once upon a time when I once randomly turned it on, so the hopes that it's simply a fuse are long...

-Wayne
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101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming Soon:
101 Projects for Your MINI Cooper
Old 10-25-2007, 01:23 AM
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Wayne,I pull my Blaupunkt and the Audi radios,with four 2" nails. The proper tool has like "fishhooks" on the ends to grab the radio and allow you to pull it out with the tools. The nails just release the 'latches" and you have to manhandle the radio out .
Love this thread, good luck.
Old 10-25-2007, 02:05 AM
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like Bob said the nails will work fine. Here is a picture of the blaupunkt release system.


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Old 10-25-2007, 03:17 AM
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That looks like the same tool that I used to pull the stock head from my '01 Ford PU. Think I got it at NAPA/Autozone/Pep.
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Old 10-25-2007, 04:17 AM
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Radio removal tool.....

Wayne,

I have a set of the DIN type radio pullers. Send me a PM with your mailing address and I will put them in the mail tomorrow.
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Old 10-25-2007, 06:47 AM
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Wayne,

The climate control panel looks similar to later model 911 and 944/951's. The full heat issue is well known to occur in these cars as these little plastic clips underneath the dash break and allow the heating/cooling flaps to the full open position. The clips are about a dollar. Many climate control units have been replaced unnecessarily. May be worth a look seeing how many of your aliments have been easy fixes.
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Old 10-25-2007, 09:10 AM
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Wayne, I usually start with a known working climate control head to see if the problem persists. Clear that then start in on the various flaps and motors.
By the way if the climate head is like 964 and up, the radio removal too also pulls the climate head.
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Old 10-25-2007, 09:32 AM
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Wayne, following the 959 progress is the most compelling read (IMHO) on the BBS in quite awhile.

It's fun watching you open it up and tinker. That must be a blast for you.
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Old 10-25-2007, 09:34 AM
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These have been great threads. Thanks for sharing .

The owners manual was a real eye opener. I had no idea it was such a limited production car or such an obviously huge technical venture for Porsche at the time. I guess seeing a couple of them in the Seattle area made them seem more "common" that they actually are. I have really enjoyed the speculation on how the original cars were put together and the later maintance or obvious lack of on this one. Mind boggling to me for such a rare car.

Glad it has found a better home @ Pelican.

Fun reading and thanks again Wayne.
Old 10-25-2007, 10:17 AM
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That is an amazingly complex car... I can count on learning something on every post, keep them coming Wayne!

angela
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Old 10-25-2007, 10:27 AM
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I just wanted to add my thanks, its a wonderful read on each days events.
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Old 10-25-2007, 11:09 AM
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Quote:
Originally Posted by fred cook View Post
Wayne,

I have a set of the DIN type radio pullers. Send me a PM with your mailing address and I will put them in the mail tomorrow.

Thanks but I ordered that radio removal set today, and if I mess with it today, I will try the nail technique...

-Wayne
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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming Soon:
101 Projects for Your MINI Cooper
Old 10-25-2007, 01:53 PM
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Quote:
Originally Posted by group911@aol.co View Post
Wayne, I usually start with a known working climate control head to see if the problem persists. Clear that then start in on the various flaps and motors.
By the way if the climate head is like 964 and up, the radio removal too also pulls the climate head.
Sweet, can I borrow a spare 959 AC control panel?

-Wayne
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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming Soon:
101 Projects for Your MINI Cooper
Old 10-25-2007, 01:59 PM
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I'm not sure if I'm going to be able to do anything on the car today, but maybe I'll shoot a brief video of the engine running and/or some shots of the contents of the toolkit.

-Wayne
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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming Soon:
101 Projects for Your MINI Cooper
Old 10-25-2007, 02:00 PM
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