Head gasket (external leak)

[Volhv]

I guess it's time for some stop leak.....
...and by that I mean a new gasket.

Porsche 944 coolant leak from head. - YouTube

Started a thread about a coolant leak I discovered a few month ago (http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/718768-oh-no.html), but could not investigate further since I was in the middle of a clutch job.
Now that the car is more of less back together, I was able to start it, and look for the coolant leak. Some have suggested that It could be a of of the temp sensors. Unfortunately I was not that lucky.

[John_AZ]

Volhv,

I was going to comment but I spent time on your blogspot and was impressed!!
944: February 2013

Going month by month it appears you have all information to get the job done.

Very nice.

J_AZ

[princej]

great blog. very well done. you have certainly done alot to that car. and the blog shows it all.

[Volhv]

Thank you.
Soon enough it will all be done. I've done so much work to this car, and only drove it 100km. The annoying part is, I had the intake and cam tower off, when I resealed everything (except the head gasket). I was going to do the head gasket also, since I was pretty much there, but figured.... if it ain't broke don't fix it.

Any WYIT's? I plan on running the engine, and soon after that removing the cam tower so I can check the lifters before they drain. I all ready have 8 hard ones waiting in a bread pan full of oil.

[rhett]

Volhv, great blog. You come across as a very thorough and considered mechanic, your work is really good. Brilliant attention to detail and well documented in your blog. Keep it up sir!

[Volhv]

I really appreciate the compliments.

So I started taking a few things apart. Everything is coming off nice and easy, since it was only last year that it was all installed.

Oddly enough, the pintle caps from cylinder 2 and 3 remained in the intake manifold. I pulled them out with an ear plug so I don't damage them, and snapped them back on. When I originally installed them the "click" was pretty weak.

[Gawernator]

For me cylinder 2's cap does that. Not a big deal. Injector one leaking... Bigger deal

[Volhv]

That's pretty crappy Gaw, sorry. So the injector itself is leaking.... that's a common problem with our injectors. WitchHunter Performance - Injector Cleaning & Flow Testing Services

[Gawernator]

I guess I manhandled it? I was really careful.. I'm not sure if I did something or if just finally died?

[Volhv]

Its time had probably come. I've been looking for a spare set locally, but no luck. Everyone here is either selling the turbo ones or the early NA. We need the 85.5-88 ones, which are 930-606-120-00, or Bosch # 0-280-150-158. If you do a search, there are some cheaper alternatives.

Today I also removed the intake manifold and cam tower. Two lifters were soft, 3 and 7. To properly inspect them I ran the engine shortly before dismantling. When I installed them 8 months ago, they were all soft. So this proves that they can not be properly inspected unless they have just come out of an engine.

I also got some picture of how to check TDC.

[Gawernator]

Yes, today one of the Ex-Porsche Pelican techs told me we have the same injector as the 930 turbo. Pelican sells the GB rebuilt ones for like $42, not to detract from our sponsor but in this case I think they're pretty overpriced, considering ********* has them for $28 each, same part number and they are BOSCH

[Stephen03]

Hey, I just did my head gasket this weekend. A few tips... I got the head off with the headers attached, I also put the headers back on with the head installed (studs still installed). Saves a bunch of time.

I bought the injector reseal kit from paragon, it appears to be the wrong pintle caps but it runs ok. Trying to find and order the correct kits if anyone has a good source.

Stephen.

[Stephen03]

PS: I am also in BC (Vancouver) if you find a good source for the injectors let me know.

[Volhv]

The rennbay injector seals are a correct fit... even if they don't go on that tight. It's like they can fall off when they're in the manifold.
Porsche 944 Injector Seal Kit - Rennbay - Porsche 944 ball joints, power steering, brakes, odometer gears & accessories

Looks like early 944 injectors are different, but close enough.
Fuel Injectors

[Volhv]

Will I encounter problems after resurfacing the cylinder head? As far as clearance is concearned? Since I've read in the manual about a thicker headgasket needed to compensate for material removed. Or will an insignificant amount be taken off by the machine shop.....

[John_AZ]

Per Porsche WSM:




Keep the cam followers/lifters in the same cam hole. When you lift the cam put a thin sheet of metal under cam --between head & cam-- and hold tight while you lift. Same on the reverse.

Keep the lifters soaking in oil with the vent hole on the side UP. Pros will mix 10% Seafoam and oil mix. Fill lifters on the vent hole with a needle syringe.

Check for soft lifters by pressing the "button". If soft and squishy--not good.
Hard is best. If needed, get good "used" INA lifters.

GL
J_AZ

[Gawernator]

I think all the injectors are cross compatible, right now I have injectors with three different part numbers total. None of which are the same as the ones I took off my car. I think they are mostly from a 930 which used the same injectors as a 944.

[John_AZ]

Originally Posted by Gawernator

I think all the injectors are cross compatible,


I might not fully understand what you mean but below is a table of injectors---varied by impediance/resistance (OHM) and flow/


right now I have injectors with three different part numbers total. None of which are the same as the ones I took off my car. I think they are mostly from a 930 which
used the same injectors as a 944.

I use the BOSCH 0280-150-158 on both cars.

Just Fuel Injectors EFI Flow Chart

J_AZ

[Dean924s]

Originally Posted by Gawernator

I think all the injectors are cross compatible, right now I have injectors with three different part numbers total. None of which are the same as the ones I took off my car. I think they are mostly from a 930 which used the same injectors as a 944.

At a minimum I would OHM them and make sure that they are all the correct resistance. Get this wrong and it can do bad things. MOST 944's use low R injectors. However the 951's are different as are the S's.

My list for 944's I have never got what the 2.7's have

Bosch injectors OHM's CC/Min Lb/hr Bar Car
0 280 150 201 2.8 240 22.82 3 82-85 944
0 280 150 158 2.1 243 23 3 85.5-91 944
0 280 150 803 4.7 370 35 3 951
0 280 150 824 low ? ? ? ? 944 - 2.7
0 280 150 911 14.2 312 30 3 968

[Gawernator]

I'll check. GB said this: Andrew,

Thank you for the email. Our process is as follows:

· Clean & Degrease Injector
· Coil resistance test
· Ultrasonically clean injector
· Reverse/back flush injector
· Spray pattern test
· Leak down test
· Static flow rate test
· Dynamic flow rate test
· Blast and polish injector
· Clear-coat injector
· Lubricate injector
· Install new components
· Package & seal
· Final inspection




Best regards,

Kerry Green
GB Remanufacturing, Inc.
2040 E Cherry Industrial Circle
Long Beach, CA 90805