[MCL968]

Most of us remember the strange mix of excitement and dread that we all experienced when we purchased our first 968. We recognized that there is a lot to know about these cars, and that we had a lot to learn. Most of us have kept learning as long as we have owned them.

 

What do you wish you had known when you purchased your car, and what are the repairs/upgrades that you feel are most important for a new owner to know? I know I learned a lot over the first two years, and I fixed things that had never failed on the other cars I have owned- issues that are peculiar and unique to the 968.

 

So, let's start a list. Below are my entries to get the ball rolling. Add items from your experiences as you see fit.

 

Things to inspect and possibly repair on your new (to you) 968:

 

01) Check and/or replace timing and balance shaft belts, belt rollers, and balance shaft seals if the belts are over 5 years old.

02) Check and/or replace water pump and thermostat.

03) Consider replacing the cooling fan switch to the lower temperature unit.

04) Replace plastic heater valve.

05) Replace the charging wire that runs from the alternator to the starter.

06) Replace the trigger wire that runs from the firewall to the starter solenoid.

07) Replace the trigger wire that runs from the firewall to the alternator.

08) Check the firewall for cracks around the brake and clutch cylinders.

09) Carefully inspect all vacuum lines for cracks and replace as necessary.

10) If over 100KMI, consider replacing the ignition switch.

11) Replace dash bulbs, clean the contact posts on the circuit board, replace the odometer gears, and redo the light tunnels.

12)?

 

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[Waylander]

not a consideration for USA cars

 

12) check the corrsion of the fuel lines where they duck behind the rear beam, they split and leak,

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[pdxmike]

I'd add

 

13) check date code on tires; replace if approaching/past 6 years

14) address any maintenance unknowns (oil (!) & filter, air filter, fuel filter, distributor cap, spark plugs and wires, brake pads, clean MAF, flush and replace brake fluid & coolant) 

15) Buy and stash a DME relay

16) even if not replacing balance belt- check orientation of balance shafts

17) Check and adjust accelerator pedal stop and cable

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[tejon007]

I would second the DME and spare relays (I have carried spares in my other cars, but I was driving the 968 back after purchase and it failed to start and as I suspected it was the DME that failed - bad location and bad weather coming - a 5 minute fix it you have the part...).


I'd also add to buy up all the parts that are now NLA and keep for spares/repairs in the future...i.e. front light covers (if you catch a stone, how you going to fix it?).

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[94SilverCab]

19) Fix the power steering leak in the right front side over the steering rack bushing.

20) Replace the clutch inspection port plug that has fallen out by now.

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[MCL968]

21) Have the Variocam pads and chain inspected and changed if necessary.

22) Consider having the head gasket changed at the same time if the car has over 120K on it.

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[pdxmike]

23) adjust (tighten) parking brakes at the rear rotors

24) gearbox oil change (6MT)

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[MCL968]

25) Clean the sunroof drain tubes.

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[Ryan]

25) Clean the sunroof drain tubes.

 

That coming from a cab owner...thorough.

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[94SilverCab]

26) Never reset the trip odometer when the car is in motion

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[Waylander]

Don't think that is true, I'm always resetting my trip in motion.


27) replace the header tank cap they leak like mad when they get a few years old

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[az968]

The trip odo gears can strip if the car is moving. But, per the owners manual the ignition must be on to reset.

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[Kaj Hallstrom]

28) Inspect starter motor and replace after 70000 miles.

29) Inspect wallet make sure you find cash in it and that it is good to go.

30) Inspect and replace (at 70000 miles) clutch and maybe some other clutch related items.

31) Inspect your credit with the bank. Make sure it's good to go and cc's are loaded.

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[Rap]

32) Get everything fixed at one time so you don’t have to worry later on! Fran oil filter.

 

STAY WITH THE PROGRAM - JAY

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[MCL968]

So, here's what we have so far. Anything else you all want to add?

 

01) Check and/or replace timing and balance shaft belts, if the belts are over 5 years old. Consider replacing the belt rollers and balance shaft seals at the same time. Gates and Dayton/Dayco belts have produced the best results for most of the Forum members. Even if you are not replacing the belts, check the orientation of balance shafts by removing the top cover and using the inspection hole on the bottom cover. It is surprising how often they are out of sync.


 

02) Check and/or replace water pump and thermostat.


 

03) Consider replacing the cooling fan switch to the lower temperature unit.


 

04) Replace plastic heater valve with an all-metal unit.


 

05) Replace the charging wire that runs from the alternator to the starter.


 

06) Replace the trigger wire that runs from the firewall to the starter solenoid.


 

07) Replace the exciter wire that runs from the firewall to the alternator.


 

08) Check the firewall for cracks around the brake and clutch cylinders.


 

09) Carefully inspect all vacuum lines for cracks and replace as necessary.


 

10) If over 100Kmi, consider replacing the ignition switch.


 

11) Replace dash bulbs, clean the contact posts on the circuit board, replace the odometer gears, and recover the light tunnels with foil or reflective tape.


 

12) If you have an ROW car (Not made for North America sales) check for fuel line corrosion where they tuck in behind the rear beam. They have been known to split and leak at that location.


 

13) Check date code on tires; replace if approaching or past 6 years.


 

14) Correct any maintenance unknowns, such as oil & filter age, air filter, fuel filter, distributor cap, spark plugs and wires. Be certain you use oil with the proper additives and good plugs and wires.


 

15) Inspect brake pads, flush and replace brake fluid if you are not sure it has been done in the past few years.


 

16) Drain and replace coolant, carefully bleed the air out of the system as per the Forum instructions.


 

17) Clean your MAF, and buy a spare DME relay to keep in your glove box.


 

18) Check and adjust accelerator pedal stop and cable.


 

19) Fix the power steering leak in the right front side over the steering rack bushing, replace bushings while you have the rack out.


 

20) Replace the clutch inspection port plug that has fallen out by now. A cut-down vent pipe plug from a hardware store works well and can be tightened so it will not fall out.


 

21) If over 120Kmi, consider having the head gasket and Variocam pads and chain changed at the same time.


 

22) If there is no replacement history, change the transmission fluid, The 6 speed transmission requires a special gear oil, use the proper stuff, replace the plug sealing washers, and expect that the plugs will be unnecessarily tight.


 

23) Adjust the parking brakes at the rear rotors. Wheels should lock tight with 4 clicks on the brake handle.


 

24) If you have a coupe, clean the sunroof drain tubes.


 

25) Avoid resetting the trip odometer when the car is in motion. Some have reported such behavior will destroy the odometer gears, others have had no problems resetting while moving.


 

26) Replace the radiator expansion tank cap. They are cheap, leak when they get old, and new ones look a lot nicer.


 

27) If your car has over 70Kmi and your starter motor sounds like it is dragging, you may have Gummy Starter Syndrome. Inspect and either lube or replace.


 

28) If over 70Kmi, inspect clutch. If clutch needs replacing, be certain to use the proper pressure plate. Consult the Forum for that part number. While in there, replace other clutch related items, such as the clutch arm needle bearings and the throw-out bearing.


 

29) If shifting seems sloppy, replace the small shifter bushings and the large nylon bottom pivot.


 

30) Get everything fixed at one time so you don’t have to worry later on, and stay up on a solid maintenance program! 

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[az968]

31) Drive the car, letting it sit is criminal. And a big disservice to yourself after doing all this maintenance.

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[Ryan]

If I saw this list I would have never bought my car. I have not done many of these things at 90k. I say do the belts and drive the car till something breaks.

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[ds968]

If I saw this list I would have never bought my car. I have not done many of these things at 90k. I say do the belts and drive the car till something breaks.

Exactly what I do.   Actually brake fluid changes also. 

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[Rap]

You could prioritize this list and do it in segments.

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[MCL968]

Just make sure you put the alternator wire at the top of the list right under belts. I have never seen a wire in as bad of shape on a car that new. And mine was from California, not the hottest part of Texas or Arizona. If you haven't checked yours yet you might want to make that a priority.

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