Test the viscous clutch before fiddling with, can be refilled, but if it leaked out once it will do it again.

Got it. Yes it has leaked out. I am going to go with the FF Dynamics fan kit. just trying to decide if I want to go with the extreme version for future engine enhancements, or just the standard version.

Nice work on your 928.

Thanks! Still more to go.

Extreme kit is on the way. It should be in next week. It will replace both fans and comes with a shorter belt. I'll post updates once it's done. I may work on the alternator rear tube and hose, and the passenger side front fender splash guard this weekend. I am hoping my lift bars come in soon. They will make it a lot easier to work on stuff. I also need to work on my odometer. I have replaced the gear in my current unit 3 times. It works for 7-10 miles and then pops off the gear somehow. I have another odometer I am going to try and use and see if it's any better. It is about the same mileage as my current one, so it should be fine. I have a leather shifter boot and trunk receiver insert on the way. I may have a line on a used fuel sending unit as well. It has not worked at all since I took it apart. The list gets shorter....and longer at the same time...

Read the odometer repair write up, something about the offset of the gear assuming its the right gear.

I got to try out my new lift bars. Very nice indeed. These will help a lot. They make it so easy to put up in the air now.
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Possibly tomorrow I'll work on the alternator rear case/tube thing. Also retry the odometer for a fourth time. Monday I'll get the fan out and get ready for the new cooling kit.

Fan kit didn't make it by Friday, and I had some other honey-do's to check off my list. I did get the alternator out and cleaned up. The new rear gasket is installed and ready for attaching the new rear cover and hose. The shielding on one of the wires to the oil pressure sensor (I'm guessing?) was all destroyed. I'm going to run some new heat shrink tubing and see if I can get it protected a bit better. Also the oil level sensor wire with that hardened brown casing over it seems to have cracked. I need to figure out something else do do with that. I cleaned up what I could wile I was in there. It does look like I have a leak on the exhaust manifold for cyclinder 4, 5, and 8 to deal with. Also some sort of port on the upper rear passenger side of the engine seems to be leaking. Not sure how to tackle those yet. The good news is the new oil pan seal looks good, and all the other repairs look good as well. I went back and torqued the rack and front end components to 68 ft lbs (from the 35 initial) while I was checking around. New lift bars are a dream! I wish I would have had them for the first part of this project, that for sure.

I need to order some more screws and foam for the drivers side splash guard for when I put that back together. The piece that had the temp sensor in it is a complete mess. I'll try and wire wheel it tomorrow and see if I can get it cleaned up. I will be ordering a transmission filter, crush rings, and a gasket this week and get that cleaned up as well. I keep finding more bonus problems it seems...

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Very nice work! That oil pan looks like new! Good luck and looking forward to updates.

Thanks! I am having a blast so far. =)

I just tried to update my garage pictures and failed. Does anyone else have problems with this? I re-sized them and even tried IE and Chrome with a fail on both. Weird.

having the same problem with the garage too :(

May be my turn soon
 

After about 5 years of storage, I have worked up the courage to try to get mu 87 S4 back on the road. Step 1 is how to begin. How do you work under the car? Do you have jacks, a hoist, other? What special tools and other equipment do you recommend I have on hand? Any other suggestions as to how I should proceed?

From Pelican technical support:
Anthony,

Yes, looks to be an issue all right. We're on it and hopefully will be resolved shortly.

Thank you

Mark Hotchkis
Pelican Parts

Well ihorp, here's a few suggestions.

1. Get a car lift and 4 jack stands. That way you can get the car up in the air and be safe. I bought a set of lift bars for my car. Go check Liftbars for details on these. Well worth the money.

2. Get a creeper and some good knee pads. You are going to be on your back a lot, and under the car moving around a lot. It helps a LOT with a creeper that you can lay on. I have a Z creeper, that is a creeper and and transforms into a rolling stool. There are many good ones out there. Knee pads help with the crawling around and up and down that will happen a lot. I've had 8 knee surgeries between my two knees, and the knee pads helped immensely.

3. Get a good set of Craftsman metric wrenches and sockets (1/4, 1/2, and 3/8 drive so you have multiple of the same size). I only suggest Craftsman because they replace them if they brake with no problems. Probably double up on 13, 15, 17, and 19 mm wrenches.

4. Search for the topic you are looking into online. There are others who have done most of these things before you. Learn from them. If you can't find something online, post here or on Rennlist. Someone will know what you are talking about.

5. Get a copy of the service manuals. There are many way to get or buy a copy. Look through the forums and figure out how to get your hands on some.

6. Take your time. If you are unsure, take a step back and make sure what your next step is. Get a game plan with how you are going to attack a problem.

7. Verify your failed part if possible. It doesn't make sense to waste money if you are not sure of the part. The "shot gunning" approach can get expensive with these cars.

8. Organize your parts/bolts/screws/etc in groups of how they came out of the car. Take pictures if you need to, to make sure you know how to put it back together. It's sort of like advanced Lego. Make your own instructions for reassembly as you take it apart and it'll come back to you easier.

9. Remember to have fun. If you are frustrated with your car or problem, you can make poor choices, or further damage your vehicle by not concentrating on what you are doing. Take a break, eat some lunch, sometimes even leaving it for the day will serve you better in the long run. This car will give you problems that can't be fixed in a few hours. Expect weeks or even months on jack stands to get the job done right. It is just part of the deal. If you want a daily driver with no problems, you may want to pick a different car. Granted, once you get some major repairs out of the way, most people seem to think they are problem free if you keep up on the maintanence. I am not there yet.

10. Double check your work. This one is tough for me because I get so excited that I have accomplished a task. I even drove out of my driveway without having torquing my lug nuts once. Luckily not too big a deal, but who knows how bad it could have been if I hadn't remembered at all. If you are working with a friend, check each other's work just to keep everyone honest. It's not that I don't trust anyone, it's just that I don't trust ANYONE.

11. Once you've tackled and completed one task, pick the next most important one. Create a budget if you need to for time and money. Get everything you need, from tools, to parts, to help/advice. Plan for bonus problems just in case. It seems every job has a "while you are in there" bonus problem. Plan for it taking longer than you hoped. Don't get discouraged. Like Dory says (from Finding Nemo), Just keep swimming.

That's my main recipe for fixing my baby so far. I am sure there is more, but this is how I've done it so far. My back ground is in Electronics Engineering and software. I have a fairly high mechanical aptitude, but this is my first car I have torn apart. I'm just a Nerd with some tools, some confidence, and some wicked Google-Foo. If I can do it, most people can do it.

Garage Issue Fixed!...
 

Carry on, this is a great thread!

Mark at Pelican

Not fixed completely
 

Hey Mark, it does look somewhat fixed. You can change the main picture and other sections, but the "additional pictures", and "external pictures" sections are still broken. Probably the same code change in those sections will fix it. Thanks!

Anthony

If those oil leaks pictured are from the back of the engine, check your cam covers. If I remember correctly...each cover has three bolts and they are most likely lose. The drivers side you can snug up from the top side, with the air box removed, but I found the passengers side much easier from below. They have a cork gasket and after snugging mine up...oil leaks were gone.

Again, great job! You have really shown the desire to get this car done and running.

Brian.

Yes, the cam seals are the likely culprit at this point. I will be checking them this weekend. Also the oil pressure sender seal, and another oil seal above the oil pressure sender in that same area. A bunch of parts will be showing up next week, then it's back to work on this baby. I have needed this week to recuperate a bit.

I haven't made much progress this week/weekend. Still waiting for parts. I don't like the look of some of the wiring in the alternator wire bundle. The outer cover to the oil over sender is cracked. The outer cover on on of the wires to the oil pressure sensor just came apart in my hands. I'm coming to put some new shrink tube on while I have is apart. I did get the belt driven fan out, so I got something done. Parts should be coming in Monday and Wednesday/Thursday this week. I did go on a wild goose chase though. A friend in the local PCA has an 85 S4 that is crashed. I was going to steal the spacers he has on the rears of his car. It turned out to be a bigger deal than planned. I would have to take the entire hub assembly because it has longer studs pressed in. Still thinking about it. The car also has S4 breaks, which would be an upgrade over mine. Front right side is totaled, but I'd only have to buy one hub, one rotor, and one caliper to have a full set. It's not the newer calipers with the "Porsche" lettering, which is what I would like, but it is an upgrade over the S brakes I have. Any thoughts on that from you guys?

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And just a peak at that new oil seal... Beautiful!
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