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NBRettie18 · Posted: Wed Jan 31, 2007 5:00 am Post subject: clutched fixed car wont start

hi i have an 87' 924s that i have been working on installing a new clutch in my auto shop class in high school. it has given me many problems and i have only been able to work on it 2 hours a day in class, plus breaks weekends etc., therefore it has been in the shop for probably about three months now. so i finally finished it put everything back hooked it all up and that it was done. but now the engine wont start and its not getting spark. the starter had low resistance so we hooked a better working one up, still wouldn't run. my teacher suggested i check the relays see if any don't work anymore which i will do tomorrow. i thought also i might not be getting fuel pressure or the fuel filter might be clogged, but my teacher said the filter wouldn't clog in that amount of time. i was wondering if any one had any suggestions; they would be most appreciated.

Smoothie · Posted: Wed Jan 31, 2007 5:32 am Post subject:

If the problem's with the starter and you've already checked+cleaned the wire connections, there can still be a grounding problem.. They ground through the starters' bolted connection to the bell housing. Clean the surfaces where the bolt heads contact the starter and bell housing, clean the bolt threads with a die and/or wire brush and clean the internal threads on the starter and bellhousing with the appropriate sized tap.
I had this problem about a year ago - It started with an actual starter problem - I replaced that with a good spare, but it still wouldn't start.. Then I wasted a day tearing into the ignition switch and various other electrics and found nothing wrong, then decided to clean and chase those starter mount bolt threads and that fixed it.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Paul · Posted: Wed Jan 31, 2007 10:33 am Post subject:

If the car is turning over and has no spark, check to make sure your reference mark sensors are installed properly and are plugged in.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

NBRettie18 · Posted: Wed Jan 31, 2007 4:25 pm Post subject:

hey, the starter is fine i don't think thats the problem, but i will try cleaning the wire connections like you said.

and what is the reference mark sensor? are you talking about the speed sensors?

dgz924s · Joined: 03 Nov 2002 Posts: 592 Location: Kansas

NBRettie18 · Posted: Thu Feb 01, 2007 3:57 am Post subject:

hey. ok so thanks for all the help i tightend up the speed sensors and started it and it worked.

but then as i was driving it around the block i turned the windshield wipers on to get some water off, then turned them off, but they didnt go off. got back to the shop turned the car off, turned the power on and they were still on. so there stuck on and it was at the end of the class so i just decided to leave it in there and try to fix it tomorrow, so i havent done anything yet to try and fix it.

dgz924s · Joined: 03 Nov 2002 Posts: 592 Location: Kansas

Wiper issue is an easy fix provided you are not prone to breaking plastic components.

Work needed..
set wheels str8 with the steering wheel
remove the horn pad
remove the SW...24mm deep socket is best
3 screws standard head in face plate removed
2 phillips screws in column cover under SW...PLASTIC
gently remove the column cover
gently pull the wiper and turn signal stalk off shaft...wires and plugs involed...careful
separate the TS from the WPR stalk
clean contacts and see if that solves it
broken...get a NEW one.
Remember to torque the SW when done

Hope this sheds a little light...GL!
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Dal Glassinger

NBRettie18 · Posted: Fri Feb 02, 2007 3:59 am Post subject:

ok i fiddled around with the wipers and it kind of resolved its self they still come on randomly so im thinking its something with the electrics.

but i have a bigger problem now. getting out of first gear is very hectic. i rev it around 2000 and slip it into gear but as soon as i let the clutch out the revs drop to below 1000 and the engine sputters and is very slow to get up to speed. getting into second and third are fine though, no trouble. i thought maybe i need to adjust the clutch pedal freeplay but im not sure that would solve it. if anyone has had this problem or knows whats wrong please help. i think i might end up just taking it to sneichder autohaus a porsche specialty shop in my city but it would be great if i didnt have to.
thank you

Smoothie · Posted: Fri Feb 02, 2007 5:16 am Post subject:

That wipers-turning-themselves-on problem is usually caused by loss of ground. The wiper switch grounds through the metal plate and the screws that hold it on. The metal plate is zinc plated and oxidises over time leaving you with an intermittant ground and wipers that come on when you hit a bump, make a turn or whenever they feel like it. Just remove each screw and scrape the metal plate where the screws make contact and/or reinstall the screws with toothed (aka- "star") washers.

Your other problem sounds tune-up related. Could be a weak coil, dist cap/rotor, plug wires needing replacement or or simply plug wire/s not fully attached at either end.
Could even be water in the fuel or your parking brake is on or out of adjustment.
Leave the clutch alone - it's self-adjusting anyway and your symptoms don't indicate a problem there.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

NBRettie18 · Posted: Fri Feb 02, 2007 11:55 am Post subject:

hey,
ok so actually my gearing is all outta whack same thing applies with first gear but i can stay in first gear for a really long time as well as second and then i go into third and its like i'm going back into first, it revs really hard and i immediately go into 4th. i think my syncros are all messed up or something.

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

Does it go backwards in 5th?
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Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

NBRettie18 · Posted: Fri Feb 02, 2007 5:24 pm Post subject:

No fourth and fifth are the only gears that seem to be right and reverse is fine too. i think it has something to do with the shift linkage, i'm going to try and adjust it on the transmission tomorrow morning.