924Board.org

[tj924]

Had the car up on stands for a few weeks recently as my clutch cable snapped & I had to save my $ to get a new one ($137 inc. postage from Performance 9). Got the clutch cable installed (had to jack up the clutch fork to get it up enough to get the cable off & on the end, that was fun!!!).

Now when I start the car there is a definite "putting" sound from the #1 cylinder & I can feel gas escaping around the plug. I have removed, cleaned & reinstalled the plug, ensuring it is tight etc, but that made no difference. The noise & gas stops when I pull the #1 plug wire off the dizzy (car runs rough at that point, so is definitely firing on all 4 until I pull the #1 wire). It doesn't feel like gas escaping from around the exhaust manifold, but my guess at the moment is that it must be (ie needs a new exhaust manifold gasket). Any other suffestions?

My research suggests that the best way to change the manifold gasket is to pull the head with the intake & exhaust manifolds attached. Is that correct? Is this achievable for a newb? If so I would need a head gasket kit obviously, does the kit typically include all the other gaskets needed (exhaust & intake manifold gaskets, cam cover gasket, exhaust downpipe gasket etc)?
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TJ
Silver '82 924 NA 5-Speed Manual

[dpw928]

Try replacing the plug as they have been known to leak between the metal and ceramic insulator.

Dennis
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81 931 5 sp
78 928 5 sp Silver
78 928 AT Euro Black

[crunchie 57]

[Mike924]

1) try the plug thing first, definitely

2) don't know for sure, but pulling the head to replace a manifold gasket seems a bit extreme to me

3) Are you running some kind of fancy clutch arrangement? A standard clutch cable here costs about £20 (AU$50)!
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1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

[Chrenan]

[Nobbi]

To replace the gaskets theire is no need to take the head off.Its not a lot off space but it is posssible.
That story with the plug is new to me, never heard about a problem like that.

Nobbi

[tj924]

Got a new set of plugs yesterday ($15 for all 4 plugs, so I thought "why not"). Changed the #1 plug but it made no difference, so it must be the exhaust manifold gasket. I thought the general consensus here was that it's easier to pull the head with exhaust (& intake?) manifolds attached due to the tight space & often difficult/impossible to remove exhaust nuts/studs. Is that not the case?

Unfortunately the clutch cable isn't made of gold, Performance 9 is the only place I could find one locally with the only other option being to have one custom made for anywhere from $80 to $160 + postage.
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TJ
Silver '82 924 NA 5-Speed Manual

[Joes924Racer]

Waite a minute do you know the price of a head gasket yet.
no you don't have to pull the head to do that stuff...you have to maybe remove the oil filter, and starter to get to the under side of the
exhaust plus the 5 lug down-pipe connection might not even have to be messed with that's a problem area where you'll brake bolts they rust
and wear away from the heat and stuff and over time become weak.
you'd be better off haven someone from the states get your parts
seems try the parts bin.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

[tj924]

Checked PET & it would appear that all I need is 4 x gaskets "048 129 589 A" ($6 each), assuming I'm not missing any studs or nuts.

Any tips on replacing the Exhaust Manifold gasket from someone thats done it? Looks like I need to pull the spark plugs, remove the heat shield from the top of the car, then get under & remove the 8 x nuts holding the manifold to the head, remove & replace the 4 x gaskets & reassemble.

I recall Ozzie saying to lower the front crossmember to gain better access?
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TJ
Silver '82 924 NA 5-Speed Manual

[dpw928]

Use the double nut technique to remove the exhaust studs. This will let you remove and replace the exhaust gakets with little or no movement of the manifold.

Dennis
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81 931 5 sp
78 928 5 sp Silver
78 928 AT Euro Black

[tj924]

[dpw928]

Put a second nut on the stud, tighten it to the other nut, then use a socket or end wrench to remove the studs. Once they are all removed, the manifold will separate from the head enough to change the gaskets.

Dennis
_________________
81 931 5 sp
78 928 5 sp Silver
78 928 AT Euro Black

[tj924]

[Lizard]

if you have never removed the exhaust before I would recommend that you replace all the studs going into the head along with the nuts, before installing coat everything with lots of never sieze.
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3 928s,

[Ozzie]

I didn't touch the crossmember when I done mine.
I replaced all the gaskets, all the studs and nuts with the head on the motor.
It was difficult and I removed the steering shaft (RHD), alternator and several heat shields. The engine pan is missing on my car but that would come off as well.
Dropped the exhaust off the manifold and actually managed to remove the manifold. I even retapped the holes for the studs.
However you should not have to drop the exhaust but just move the manifold to over enough to replace the gaskets.
The lower nuts are a real pain to get to tighten but it is do-able.
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance