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Orient Express

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Everything posted by Orient Express

  1. Orient Express
    To add to the troubleshooting, the 996 intake runners and the center intake are held together with rubber bellows. Check them for tears. This is very common especially with older or higher mileage engines. Good news is that they are very easy to replace.
  2. Orient Express
    My 60K service cost me $150 and 2.5 hours of my time. Check out the DIY section of the board on how you can do the same thing.
  3. Orient Express
    Essentially the DIY consists of: 1. Remove transmission 2. remove & replace the pressure plate and clutch plate which is attached to the flywheel. 3. remove & replace the throwout bearing in the transmission bell housing. 4. replace transmission. done. Total time 4 hours. let me know if you have any questions.
  4. Orient Express
    To add another data point, My 2002 996 Cab has not one piece of crap stuck in its radiator after 5 years and 63,000 miles. Why? because the car wears a bra which has a nylon mesh that covers the radiator intakes. With the bra, all I ever have to do is to squirt the hose in there every once and a while to clean out the dust. Having the car wear a bra keeps the radiators clean as a whistle!
  5. Orient Express
    The window thinks the door is closed all of the time because the door latch micro switch has issues and is acting like the door is closed and latched. The switch may be just dirty and stuck or may be defective.
  6. Orient Express
    Jeff: The broken one is the supply line from the intake plenum. You probably have a vacuum leak right now. To help you trace it, here are some pictures of what it looks like. The broken line goes to that white vacuum backflow preventer on the intake. It may have one or 2 supply feeds on it depending on whether or not the car has PSE.
  7. Orient Express
    Have you tried using the Search Tool
  8. Orient Express
    Loren: While the door micro-switch may be a fault, it is unlikely. I would suggest that the door micro-switch is just fine, but rather the cable on the window regulator is stretched enough that the 1/8th of a turn that the motor makes when the door is opened is no longer enough to overcome the cable slack. A way to test this is: First verify that the window does not go down when either the interior or exterior door handle is plulled. It is extremely unlikely that both micro-switches have failed, so if it does not go down with either door handle being pulled, it means the regulator cable is probably stretched. Next with the door open and the window rolled up, push the window glass down as far as it will go, taking out the cable stretch slack. Close the door. If the window pulls itself back up then the cable is just stretched and the micro-switches are fine. The fix for this is either: 1. Replace the window regulator mechanism. 2. Adjust the window regulator cable. Where the cable goes into the regulator gearbox there is a cotter pin holding the bowden tube it to the gearbox. The cable is in the bowden tube. By pulling out the cotter pin, and pulling the bowden tube tight, but not too tight, and replacing the cotter pin, you can take out the slack on a old regulator, and it will be just like new. You do not have to remove the regulator to make the adjustment, just the interior door panel. This method is faster and cheaper (like free) than replacing the entire window regulator. Eventually the regulator will need to be replaced when the cable is stretched too much, but this will get you a few more years out of the regulator you have. A stretched regulator cable is very common on Porsches, VWs and Audis. They all use essentially the same regulator mechanism. The drivers side is more common than the passenger side. There are several DIY articles on how to remove the interior door panel, and on how to replace the regulator. Just use the search tool to find them.
  9. Orient Express
    Here is a discussion on the subject
  10. Orient Express
    Your 02 car has a 60K plug replacement interval (the +4 electrode plugs last 60K +). If you really feel that 30K replacement buys something, then save some money and get the older 30K plugs that were used in the 99 though 01 cars.
  11. Orient Express
    Correct. A double-click on the key fob disables the interior monitoring, and gives you a beep to let you know that full security is not in effect.
  12. Orient Express
    Check to see if your brake lights come on. You may have a bad brake pedal light switch. This is a common issue.
  13. Orient Express
    DIY Throttle Body cleaning One of the problems that I see with many 996/986/997/987 owners complaining about is a lumpy or erratic idle and sometimes sluggish acceleration. I have a quick cure for this problem. In fact, this cure will work for any car that has a throttle body. The issue is that over time a sludgy gunk will build up in the throttle body where the throttle butterfly opens and closes. This gunk will eventually change the airflow characteristics of the gap between the butterfly and the throttlebody Author Orient Express Category Carrera (996) - Maintenance Submitted 08/14/2007 04:06 PM Updated 03/17/2017 05:14 AM
  14. Orient Express
    One of the problems that I see with many 996/986/997/987 owners complaining about is a lumpy or erratic idle and sometimes sluggish acceleration. I have a quick cure for this problem. In fact, this cure will work for any car that has a throttle body. The issue is that over time a sludgy gunk will build up in the throttle body where the throttle butterfly opens and closes. This gunk will eventually change the airflow characteristics of the gap between the butterfly and the throttlebody which will cause the erratic idle. In addition, this gunk can cause the butterfly the stick as it opens which will effect acceleration. The car's DME will compensate for this buildup over time, but if it gets too thick, then the "Throttle Adaption" will reach its limit, and will throw a code. Many times people think that it is the MAF that is bad, when it is just a dirty throttle body. Notice that the butterfly valve is slightly cracked open. This is for the idle airflow, and that crack can get clogged because of the gunk buildup. The solution is to remove the air cleaner box for access to the throttle body, and simply clean the throttle body with spray carburetor cleaner. Open the butterfly valve with your hand, and wipe out all of the gunk on the backside of the valve, and the inside of the throttle body. You will see a dark brown ring inside the throttle body. This is the buildup you want to remove. Take a rag, wet it with carburetor cleaner, and wipe out the gunk. Be sure to get the edge and the back side of the butterfly valve as well. You will know when you are done because the surfaces that you are cleaning are polished, and easy to see if there is stuff left on them. Here is a picture of what your throttle body should look like after it is cleaned. Notice how shinny the inside is. Don't worry if you spray too much in the engine, when you fire the engine up, all of that stuff will burn off in the combustion chamber. Where does the gunk come from? It is residue from the crankcase vent opening that is right there behind the butterfly. The reason it is there is because there is high vacuum there that will suck the crankcase oil vapors back into the combustion process of the car. Over time oil solids will accumulate there and will form a sticky lip around the opening. This cleaning should be part of your 30,000 mile maintenance as a minimum. However if you have never had your throttle body cleaned, try doing this weekend. You will be amazed at how much better your car runs.
  15. Orient Express
    It is not a seal. The windshield is bonded to the frame. What is warped is just the top of the plastic cover that is between the windshield and the trunk compartment. If your car is still under warranty, then your dealer will replace it. If not, it is just a plastic piece that you can replace yourself. It is held in with a couple of screws, and the wiper arms have to be removed to get it off.
  16. Orient Express
    Texaco DEX-COOL is a G12 coolant same as Porsche or Pentosin and costs less than $15 a gallon.
  17. Orient Express
    On the 987 there is not a relay anymore, it is controlled by the DME. If you want to have the exhaust in the loud position all of the time, just unplug the electrical connector from the vacuum valve switch that controls the exhaust flapper valve.
  18. Orient Express
    Why don't you just put the cup in the front cup holder instead of the back one? It will fit fine there.
  19. Orient Express
    To raise the wind, it is just one touch, but to lower it, you have to keep your finger on the button the whole time.
  20. Orient Express
    The only issue you will face with using a 996 hardtop on a 997 is: The 996 hardtop will probably have the older style "Pin" latch for the rear attachment points. The 997 will not have any mating latch mechanism installed. You will have to purchase and install the updated threaded bolt rear attachment mechanism on the top and the car. Refer to TSB 6117 for more details. It is a simple modification to do. Here is a picture of the new and the old attachment methods. The other minor issue is that the front alignment pins on the hardtop that fit into the slots on the left and right sunvisor mount in the windshield header have slightly different shapes to them. They will fit, but it is unclear how tight the fit will be. Other than these 2 issues it is PnP.
  21. Orient Express
    This is accurate for early 996s that came with a hardtop from the factory. When the hardtop became optional, and the latching mechanism had to be installed in the car, the latch changed from a pin to a captive bolt. In 2005 there was a TSB issued for securing the hardtop with this new latching mechanism (TSB 6117 - Modified Rear Hardtop Locks). The new latching mechanism is an 8mm captive bolt that screws into the receiver on the car. This is why there is a torque specification for tightening the bolts on the top. The new mechanism are parts A & B, and the old ones are C & D. The new parts are available as a kit and will work on both 996s and 997s. I had this part installed on my 2002 996 Cab (under warranty no less!) because of problems in keeping the top from flexing and making creaking noises. The new bolts secure the top on quite firmly and quietly. But care must be taken not to over tighten the bolts.
  22. Orient Express
    For the amount you need to add to top off the expansion tank, just add some distilled water. The mixture of coolant to water will be just fine. Enjoy Parade.
  23. Orient Express
    Yes.
  24. Orient Express
    Sounds like the previous owner drove the $hit out of this car. Normal life of a clutch plate is between 160,000 Kilometers and 200,000 Kilometers. Anything less points to a clutch system that has been used in a severe environment. The oil usage also sounds a bit high as well. It is not unusual to see 996s that only use 1 qt in 25,000 KM.
  25. Orient Express
    If you have mixed coolants (especially organic and non-organic coolants), it is wise to drain that mix out and refill with a 50-50 mix of G-12 coolant and distilled water. There are several places you can get G-12. One is your Porsche dealership (most expensive), but you can also get it cheaper at any VW or Audi dealership, or the most economical version is getting a gallon of G-12 under the Texaco Dex-Cool brand. Dex-Cool is available at any auto parts store or Wall Mart.
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