Exhaust manifold leak

[chris84944]

Hey

I just purchased a 84 944 in fairly good condition. I had it inspected by a porsche mechanic before I bought it and he gave me the thumbs up, but when I got Emissions/Safety they found a leak in the exhaust manifold. Isn't that something he should have caught?

Anyway I don't have the money for a new one right this second and I was looking for advice on buying a used one. Any recommendations as far as if its a good idea to go used, any recommendations for a used parts place, etc.

Also I was thinking about buying the quick fix **** and sealing it up for now until I can replace it with a new one. I figure If I'm going to replace it anyway then whats the harm in using this for now so it will pass inspection. Any thoughts on this? It goes against my general feelings about repairing things the right way, but its also my daily driver and If I don't pass inspection then I will be out of a car.

Lastly my car is having difficult idling (Idle is way low and sometimes dies) when engine is cold. Is this something that can be explained by an exhaust leak or should I be looking for something else?

Thanks for all your help

Chris

[SoCal Driver]

Depends on where the exhaust leak is. If it's in steel tube headers and not the cast iron ones then these need to be welded or you need to get the cast iron ones. If the exhaust leak is after the headers then the steel tubing can be welded or patch or replaced.

Cold low idle is because your idle control valve is sticking and/or not working. It's under the intake manifold bolted to the engine block. There is another current thread about one with a broken wire. Note that there is a difference between early 944's and later (85.5 and later) 944's idle control valves. Your early valve has a heater inside that causes a bi-metallic spring to expand and close off a blade valve.

[Razorback1980]

First off, welcome to the forum.

The thing you really need to worry about the most isn't the headers but the timing and balance shaft belts. These are critical for your engine as it's an interference engine so these need to be changed every 30,000 miles or two to three years. Find out from the previous owner when this was last done because it's a 2000 dollar repair bill if they break.

Also take advantage of the search button at the top of the page, almost every problem is in here somewhere although sometimes it's hard to find. If you have the steel headers, then there are a lot of us that were in the same boat as you are. The problem will probably be the 1/4 header and it's fairly easy to weld if you know anyone with a welder although on mine, I had to cut off a gusset before I could get to the crack and then weld it back on when finished. All in all, it took me about 15 minutes. No need to purchase a new header if this is the problem. If cast and broken, then check ebay or I might be able to find a salvage yard reasonably close that will have a set for little money, just let me know if you want me to help you with that.

Here are some links that have a ton of information about your car that may prove to be quite helpful along with this forum.

www.clarks-garage.com
http://www.connactivity.com/~kgross/FAQ/944faq05.html

And the technical section of this forum has many articles along with electrical diagrams for your car as well.

Again, welcome and come back often.

[chris84944]

Cool thanks for the advice

First of all, how do I tell if it is cast iron or steel-sorry for the newbness of the question but quite frankly I'd like to know and I don't.

Secondly, In response to SoCal Driver, You said the low cold idle is the idle control valve sticking or not working. I looked around on the forums but I can't find anything addressing that problem. In my Haynes Manuel I can't find anything either. Can you offer me any advice as far as checking/fixing/replacing it? Or perhaps a link?

[jwade944]

I believe that only the 1983 cars had cast iron headers, so yours should be steel. I have a set of steel headers that have already been repaired and a used idle control valve. I'll send you both for $100 plus shipping. You will have to remove the intake manifold to replace the idle control valve.

[Razorback1980]

Wait for them to cool down (you already knew that didn't you? ) then run your hand over the headers. IF they are smooth, then you have steel ones, if they are rough, then you have cast iron.

[Dougster]

Welcome Chris.
These guys are great here and know these cars inside & out but also take time (alot) to read back posts about the GREAT 944 series Porsche.

Simply a wealth of info here and in those links provided...

*Also heed Razorback1980 advice...
Check that timing/balance shaft belt(s) ASAP!

Enjoy and take care of your 944 and you will love her deeply!