[BMWRider]

OK, so "operation maintain" has begun.



For quick background I have a "new to me" 1993 high mileage coupe (170,000+) that though well maintained by the records, was in need of a lot of TLC mechanically.



I started by replacing the starter that gave up the ghost in my driveway. I had to construct a harness because apparently the harness is no longer available.



I then installed the Bulldog alarm addition. No worries and everything came out great. My hatch even pops.



I deleted the rear wiper and installed the bung. (anyone want the old setup for parts, its yours for the cost of shipping).



I replaced all the dash lights. I put in the LEDs for the main lights.



Then came the waterpump. What a pain in the butt. I have replaced many waterpumps in my life, on everything from Paxman Diesel Engines to 440 Hemis. But this one is kicking my tail. I began by removing the airboxes, the radiator, all the hoses, the plastic on the underside, and every other obstruction I could. There is quite a bit of room once you do that. Then the power steering pump belt came out along with the alternator belt. I pulled the covers and realized this was no normal waterpump change out. Off to the manual and this site. I love the car, but Porsche's manuals blow chunks. I am no neophyte to manuals having worked on everything from F-18s to 110' WPB Coast Guard Cutters but I am literally lost half the time I am in the manual. Anyway between it and this site I realized I better order the Shaft lock. So it is ordered. Now come my questions.



Whoever maintained the car before me put standard coolant in the radiator. Needless to say with the cooling system open, most if not all of it is gone. I have flushed it with a low pressure hot water flush, followed by distilled water. I see no particulate coming out of the radiator or the engine's water jacket. Should I still have the radiator professionally cleaned?



I ordered all the belts along with the shaft lock, how important is the Porsche tension tool? I have a good eye for belts and proper tension, but after reading here I am concerned. If it is critical, should I purchase it, or does someone have one I can borrow?



As I am working on the engine I am cleaning everything I can get to. I see that there is no oil leaking anywhere but my struts are in rough shape. No punctures or rips, just old and worn. I have been following other threads and plan to change those out next. Is this a job that will make the old tech feel like an idiot like this waterpump has? Or is it as straight forward as it looks?



Anything else I should do while it is torn down this far? I will check the rollers, though they all seem to look good.



There will be more, and I will take pictures when the weather changes. Anyway it is nice to learn a lot about this car, and working on it is the only way you can really learn about your machine.

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[sasilverbullet]

See my responses in-line:





I replaced all the dash lights. I put in the LEDs for the main lights. - hmmm, I'd sure like to see some pics and an explanation of what you did.



I love the car, but Porsche's manuals blow chunks. - in total agreement there!



Whoever maintained the car before me put standard coolant in the radiator. Needless to say with the cooling system open, most if not all of it is gone. I have flushed it with a low pressure hot water flush, followed by distilled water. I see no particulate coming out of the radiator or the engine's water jacket. Should I still have the radiator professionally cleaned? - this is a slippery slope, the more you have cleaned, the more might leak. Personally, I'd just home flush the thing and put in the correct coolant using purified water.



I ordered all the belts along with the shaft lock, how important is the Porsche tension tool? I have a good eye for belts and proper tension, but after reading here I am concerned. If it is critical, should I purchase it, or does someone have one I can borrow? - ok, this is a BIGGY and we'll all forgive you cuz you're a newbie to these cars. You NEED to either have someone with the tensioner tool that knows what they're doing adjust it, or, you bring it to the shop and have them do it.



As I am working on the engine I am cleaning everything I can get to. I see that there is no oil leaking anywhere but my struts are in rough shape. No punctures or rips, just old and worn. I have been following other threads and plan to change those out next. Is this a job that will make the old tech feel like an idiot like this waterpump has? Or is it as straight forward as it looks? - struts are easy



Anything else I should do while it is torn down this far? I will check the rollers, though they all seem to look good. - check ALL the rollers, you'll find some that seem like they're going bad, replace them. Check alignment of all the rollers also.



My personal recommendation is to let an EXPERIENCED shop do any timing/balance belt work. I've owned three cars like the 968 and have seen a lot of horror stories for backyard mechanics like us trying to do the belt thing.

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[Ryan]

Welcome aboard Mike,



The belts are strange. timing is self tensioned if the tensioner is not leaking. You have to reset it in a vice. (read compress) The balance shaft belts seem loose when they are correct, so that might just surprise you. I would use the tool and be safe. I second silverbullits comments about the rollers.

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[BMWRider]

[quote name='sasilverbullet' date='Oct 17 2006, 02:22 PM']hmmm, I'd sure like to see some pics and an explanation of what you did.[/quote]



Well I wish I had taken some. It was a relatively easy process. I started off trying to use "6 LED lamps," saw the break down on a 928 site and thought it might work. I was very unhappy with the results. I ended up ordering the kit from Jager Engineering. A bit pricey but it worked out great. The lights are in and working. Dimming is not as much as I'd hoped for. I did go with blue lamps, not sure why but I like it. I am likely to replace all my lamps with LEDs as time permits. I like the reliability factor, and the newer bulbs do not have the limited field of view that older bulbs do.

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[968rz]

I agree with everything everyone said, but I would like to inject that when I had to replace my w/p, I had no way to get a tension tool and being an ex-auto tech; I did the balance belt without it (PITA) it took 3 tries (too tight, too loose-scary when the belt popped of <img src="/forum/images/smilies/968/ohmy.gif" class="smilie" alt="" /> , just right). It’s been 8000 miles since then and no problems <img src="/forum/images/smilies/968/unsure.gif" class="smilie" alt="" /> . I guess what I'm saying is try to get the gauge it will save you allot of grey hairs <img src="/forum/images/smilies/968/sad.gif" class="smilie" alt="" />

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[BMWRider]

Belt tool on order, I will fill the radiator with 55/45 Phosphate free, I promise to take more pictures, and right now the car sits in the garage on ramps. I hate waiting for parts and tools.

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