Overflow Coolant Tank Replacement

kdpav · 08-24-2007, 09:32 AM

Hello again.

I finally was able to look at my 80 928 today. I bought it last Saturday and had to leave town for work that same evening.

I think I found the source of my fuel smell. The censor on the #1 intake manifold appears to be leaking. Replacing it looks pretty straight forward. If any one knows of any gotcha, please share.

I also noticed that my overflow coolant tank is leaking. The tank is wedged under the left fender. I was hoping to get at it from underneath. Is that accurate?

There are a lot of other issues with it, but before I send out a larger laundry list, I'm going to do some troubleshooting on my own. Looks like some of fuses are burned out or in crappy condition. So I'll start there...

Thanks and I hope you have great weekend,

David

Danglerb · 08-24-2007, 05:58 PM

Overflow tank replacement takes some work, and small fingers and/or universal joints and socket extensions. Once in you will really want to replace EVERYTHING in the area.

Nicole replaced her's a few weeks ago, if she doesn't post I'lll see if I can find the old thread.

I'm not sure which sensor you mean? See if you can point it out on one of the L jet diagrams.

http://www.pelicanparts.com/PartsLookup/HTML/subcat/928_USA_78_82_KATALOG.htm

kdpav · 08-25-2007, 07:27 AM

Thanks for the advice.

It's actually the injector for cylinder 1. My bad. Any advice on injector replacement would be very much appreciiated...

Thanks,

David

SeanR · 08-25-2007, 08:44 AM

Quote:

Originally Posted by kdpav

Thanks for the advice.

It's actually the injector for cylinder 1. My bad. Any advice on injector replacement would be very much appreciiated...

Thanks,

David

Until you have that fixed, please don't drive it. If one is leaking, I would venture a guess that all of the seals are bad.

kdpav · 08-25-2007, 02:01 PM

The other injector housings appear to be dry.

I'm assuming a single injector cannot be worked on independently and I'll need to take out all 4 at the same time.

Maybe while that's off It might make taking the coolant tank out easier...

Danglerb · 05:49 PM

Don't drip and drive.

Try giving each of the short hoses a little squeeze with a pair of pliers just after shutting off the motor. (with the usual safety issues)

80 has a fuel rail with a barb and 2" of hose down to each injector, IIRC. If it hasn't been done in say the last 5 years, all those hoses plus the U in the rear between the rails should be replaced. Roger at 928Rus.com made up and shipped about 100 kits after a car fire thread on rennlist.

If the injector body is leaking, it has to be replaced. Even if it isn't, cleaning them and replacing all the orings and pintles when you do the hoses is a good idea.

I am looking at ways to convert to a more modern injector with clip style fuel rails, but haven't gotten into it yet. One old style injector from Porsche is about the same cost as a modern set of 8 from many good suppliers.

Nicole · 08-26-2007, 12:21 AM

Hi David:

Yes, replacing that tank is a bit of a nightmare! There is very little space - at least on the S4 - and so many things connected to it, under it, or around it...

My suggestion is that if you have not replaced your coolant lines in the last 10 years, do this at the same time. Also order a windshield washer filler neck, because you can be sure the metal part inside it has rusted out and will sooner or later clog your windshield washer pump.

You'll have to remove this piece from the wheel side of the fender, but that'll give you a bit more room to work on the engine side.

Either way, replace everything and anything rubber in its vincity. You would regret it otherwise...a If you want more detail, do a search on the rennlist 928 message board!

Best of luck!