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924RACR
Joined: 29 Jul 2001
Posts: 8995
Location: Royal Oak, MI, USA
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 Posted: Fri Oct 17, 2025 11:48 pm Post subject: |
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You might've simply not had the correct thread for the metric - agreed, I think they're M5...
For an oil pan, probably someone breaking a car on here... they don't tend to break if you don't hit them on things... LOL
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype |
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Sat Oct 18, 2025 1:29 am Post subject: |
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| 924RACR wrote: | You might've simply not had the correct thread for the metric - agreed, I think they're M5...
For an oil pan, probably someone breaking a car on here... they don't tend to break if you don't hit them on things... LOL |
Awesome, I'll have to take the die kit and clean the threads up back to an M5, and imma just pray to all the porsche gods for now and I'll go hunting for oil pans when we get there
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Just trying my best to figure this out without total failure 
Poppy the '82 924 Resurrection in Progress |
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Raize
Joined: 18 Sep 2013
Posts: 411
Location: Scotland
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| Posted: Sat Oct 18, 2025 5:22 am Post subject: Re: Where do I go from here? |
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| PopUpProject wrote: |
List of disappointments discovered:
-AC has quite literally been hacked out of the car
Gets in the way of the supercharger anyway.
-O2 sensor wiring also got chopped -> probably why she runs like crap and sounds like she has a nasty vac leak (still need to smoke test and see if there's a vac leak because me thinks I have a few of those as well)
You can replace that whole system with a simple orifice.
-the fuel pump rewiring deserves a separate post because I am probably going to need every single persons help figuring out wtf they have done to this thing.
I don't think there is anything wrong to be honest.
-need to redo the drums, shoes, cylinders, and whatever else goes on in there most likely
Go 5-bolt
-almost all hardlines need redone for brakes
Easier than it sounds, buy this:
https://www.ebay.co.uk/itm/306357430674
-side markers were rednecked -> now fixed-ish with proper pigtails and connector plate things for the bulbs, but don't have the booty on the engine side of the passenger harness so now going to be heatshrinked for protection
-all of the window switches are aftermarket and none work -> going to have to go hunting with the voltmeter and test the switches and begin that rabbit hole
You'll get used to doing wiring. Literal VW Rabbit hole in a lot of cases.
-need a new sway bar (probably cuz this one looks questionable)
-need all new sway bar bushings (completely missing one, ones split, and the two others look decent at best)
-need both front tie rods and wheel bearings
Can be done during 5-bolt conversion
-my heat shield is in about 10 pieces hanging on for dear life
Butcher some sheet metal into shape. Nobody will see this.
-I got oil leaking from somewhere on the engine, basically the whole things coated so I sprayed and prayed with brake clean til I ran out
Learn to ignore things like that. If there is no puddle it's fine.
-redoing the shifter and all those bits are going to absolutely suck ass
It's not that bad.
-aftermarket-possibly-universal radiator with what looks like oem fans and the driver side fan's wiring has been knicked and the wiring is very corroded
Fit a 944 aftermarket aluminium rad, theyre only like $150 and theres guides on this forum.
-ground strap is holding on by a thread
5 minute job
So. uh. where do I go from here? I quite honestly want to curl into a ball and cry. I knew she was rough and she was going to need a lot of love, but I didn't think it would be THIS MUCH. I also don't even know where to start now because of above.
TLDR: I regret life decisions and need help figuring out where to start because this needs wayyyyy more work than what we originally thought. |
I replied inline above but tbh I would only do all this if the bodywork is good and it doesn't need a million weld repairs as well. |
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Sat Oct 18, 2025 7:16 am Post subject: Re: Where do I go from here? |
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| Raize wrote: |
I replied inline above but tbh I would only do all this if the bodywork is good and it doesn't need a million weld repairs as well. |
Somehow her body is actually really good, I think that's the only reason I've decided to still pursue this besides being down the research rabbit hole already. She has surface rust because Ohio + Salt = no fun and rust on all the bolty bits but I can't poke through anywhere and peaking through the air vent holes she looks good! Once I get some glue for the rear seats were gunna rip out what "backseat" I have left and see if there looks good. The trunk under the carpet looks good and I'm going to have to attack the tire storage bin with a hammer to knock the nice dent out.
I'm concerned about where her seat rails attach in because those have turned to dust but there was also a giant salt spot on the carpet so I'm guessing the rust came mostly from there because underneath looks pretty good.
I'm going to attempt the shifter arm and new bushing today because I have the parts for that already. Hopefully work the side markers back to a M5 since they've rusted to like M5.5 Then I still need to pressure test the used expansion tank.
I'll report back with my findings and success or lack there of tonight
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Just trying my best to figure this out without total failure
Poppy the '82 924 Resurrection in Progress |
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Sat Oct 18, 2025 2:03 pm Post subject: Re: Where do I go from here? |
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| Raize wrote: |
-O2 sensor wiring also got chopped -> probably why she runs like crap and sounds like she has a nasty vac leak (still need to smoke test and see if there's a vac leak because me thinks I have a few of those as well)
You can replace that whole system with a simple orifice.
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What orifice do you speak of? Because I definitely need to either replace the whole thing or somehow figure out a way to make this thing not cranky after we smoke test her and fix the vac leaks.
Putting in the new shifter was surprisingly easy until it wasn't. I followed the instructions from only944 word for word and according to Kyle (only944 dude I've been talking to thanks to the shifter not having hardware originally) they should have been the same. Yes, I emailed him to triple check since the pics were from a 944 and asked if the 82 924 would be the same process and he said yes. I get all the way to the end where you check if all 5 gears and reverse exist andddddddd I lost 5th and reverse. Like not even close to getting over to 5th gone. We ended up flipping the shifter arm to be on the passenger (right) side of the car and we got 5th and reverse back.
Anyone know if thats a normal thing we 924s have to do or why I would have needed to do that? I'm going to assume no because the shifter arm was originally on the driver side. I have the new shifter linkage from them as well so if its a linkage issue I might already have the fix? The shifter bushing from porsche was also slightly different. I'm not sure if my old one got a curve underneath from over time or if these things are meant to be curved but the new one was not curved.
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Just trying my best to figure this out without total failure
Poppy the '82 924 Resurrection in Progress |
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924RACR
Joined: 29 Jul 2001
Posts: 8995
Location: Royal Oak, MI, USA
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| Posted: Sat Oct 18, 2025 8:30 pm Post subject: |
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You mean the shift lever (part the shift knob goes on)? Parts diagram seems to show it entering the shift rod (the part that goes back to the trans) from the LH side.
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype |
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Raize
Joined: 18 Sep 2013
Posts: 411
Location: Scotland
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| Posted: Sun Oct 19, 2025 6:25 am Post subject: Re: Where do I go from here? |
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| PopUpProject wrote: | | Raize wrote: |
-O2 sensor wiring also got chopped -> probably why she runs like crap and sounds like she has a nasty vac leak (still need to smoke test and see if there's a vac leak because me thinks I have a few of those as well)
You can replace that whole system with a simple orifice.
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What orifice do you speak of? Because I definitely need to either replace the whole thing or somehow figure out a way to make this thing not cranky after we smoke test her and fix the vac leaks. |
Well, I actually used a needle valve from ebay (£10 needle valve) - you just get rid of the frequency valve on the side of the fuel distributor and put the needle valve instead.
By doing that are basically converting it from a closed-loop feedback Lambda system into CIS-Basic with no lambda feedback but you also have the benefit of being able to adjust your air fuel ratio using the needle valve.
I don't know of anyone else having ever done this but it's worth considering as it's dirt cheap and eliminates a lot of complexity.
Does your fuel distributor have the WUR return piped into the main return or does it go to a separate port? |
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scm924s
Joined: 22 Oct 2010
Posts: 296
Location: Gloucester UK
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| Posted: Mon Oct 20, 2025 5:51 pm Post subject: Re: Where do I go from here? |
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| Raize wrote: |
Well, I actually used a needle valve from ebay (£10 needle valve) - you just get rid of the frequency valve on the side of the fuel distributor and put the needle valve instead.
By doing that are basically converting it from a closed-loop feedback Lambda system into CIS-Basic with no lambda feedback but you also have the benefit of being able to adjust your air fuel ratio using the needle valve.
I don't know of anyone else having ever done this but it's worth considering as it's dirt cheap and eliminates a lot of complexity.
Does your fuel distributor have the WUR return piped into the main return or does it go to a separate port? |
Bit puzzled here, I do not believe that any Euro spec cars had a fuel distributor fitted as OE with a frequency valve and I didn't think US cars had them either?
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1984 n/a Ruby Red Metallic
1988 924S Guards red- sold
1986 924S Guards Red - sold
1984 n/a Black - sold
1980 n/a Le Mans#1 - sold
1980 n/a Le Mans#2- sold
1977 Martini - sold |
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Raize
Joined: 18 Sep 2013
Posts: 411
Location: Scotland
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| Posted: Mon Oct 20, 2025 11:35 pm Post subject: Re: Where do I go from here? |
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| scm924s wrote: | | Raize wrote: |
Well, I actually used a needle valve from ebay (£10 needle valve) - you just get rid of the frequency valve on the side of the fuel distributor and put the needle valve instead.
By doing that are basically converting it from a closed-loop feedback Lambda system into CIS-Basic with no lambda feedback but you also have the benefit of being able to adjust your air fuel ratio using the needle valve.
I don't know of anyone else having ever done this but it's worth considering as it's dirt cheap and eliminates a lot of complexity.
Does your fuel distributor have the WUR return piped into the main return or does it go to a separate port? |
Bit puzzled here, I do not believe that any Euro spec cars had a fuel distributor fitted as OE with a frequency valve and I didn't think US cars had them either? |
Some of the US cars had a K-Jet Lambda FD with frequency valve.
Mine is using Volvo 240 Turbo K-Jet FD because I needed way more fuel than OEM could ever give but the concept of just running the FV at a fixed flow rate applies to any Lambda-style FD. |
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Mon Oct 20, 2025 11:38 pm Post subject: |
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| 924RACR wrote: | | You mean the shift lever (part the shift knob goes on)? Parts diagram seems to show it entering the shift rod (the part that goes back to the trans) from the LH side. |
Yeah the shifter lever. Diagrams all show it on the left hand side, I took it apart with it on the left side, and then when I put the only944 lever and the new bushing in on the left I lost 5th and reverse. We flip her over and bolt her in on the right and we got 5th and reverse back
*edit* I realized pictures might be a tad useful. I didn't take that any pictures other than these ones because didn't realize until we couldn't get to 5th that I should have been taking pics along the way. oopsies https://drive.google.com/drive/folders/1gaKqUy91cP_RkcnDDwnDeNYi50nMTSTy?usp=sharing
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Just trying my best to figure this out without total failure
Poppy the '82 924 Resurrection in Progress
Last edited by PopUpProject on Tue Oct 21, 2025 8:19 am; edited 1 time in total |
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Mon Oct 20, 2025 11:50 pm Post subject: Re: Where do I go from here? |
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| Raize wrote: | | scm924s wrote: | | Raize wrote: |
Well, I actually used a needle valve from ebay (£10 needle valve) - you just get rid of the frequency valve on the side of the fuel distributor and put the needle valve instead.
By doing that are basically converting it from a closed-loop feedback Lambda system into CIS-Basic with no lambda feedback but you also have the benefit of being able to adjust your air fuel ratio using the needle valve.
I don't know of anyone else having ever done this but it's worth considering as it's dirt cheap and eliminates a lot of complexity.
Does your fuel distributor have the WUR return piped into the main return or does it go to a separate port? |
Bit puzzled here, I do not believe that any Euro spec cars had a fuel distributor fitted as OE with a frequency valve and I didn't think US cars had them either? |
Some of the US cars had a K-Jet Lambda FD with frequency valve.
Mine is using Volvo 240 Turbo K-Jet FD because I needed way more fuel than OEM could ever give but the concept of just running the FV at a fixed flow rate applies to any Lambda-style FD. |
We have reached the point where I don't understand what yall are talking about. I gotta do some googling of terminology here and dig through my manuals before I sound more dumb than I normally do.
I have a fuel pump switch that we discovered is quite literally a switch directly plugged into the female portion of the relay block thing (need to figure out a better way to do this so the car doesnt catch on fire), the bosche pump (stupid thing buzzes so loud after we flip the switch but not loud enough that I hear it with the car running) up in the engine bay, whatever mess of wires and filter thing is behind the wheel well, and I'm not sure what else fuel system wise.
In its current state it does the things and my fuel gauge works, honestly kinda afraid to mess with it as I've seen some of the posts of struggles, but I need to figure out what and how this actually runs fuel because its funky
*edit* WUR is a warm up regulator. Learned a new acronym. I still gotta learn more about the lambda system yall speak of, but the bosche pump is the k-jet? I think? I'll have to carefully poke around and see if I can find some more information on the thing itself. I also have to locate where the WUR exists in my engine bay and follow where that goes
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Just trying my best to figure this out without total failure
Poppy the '82 924 Resurrection in Progress |
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Raize
Joined: 18 Sep 2013
Posts: 411
Location: Scotland
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| Posted: Fri Oct 24, 2025 8:13 pm Post subject: Re: Where do I go from here? |
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| PopUpProject wrote: |
I have a fuel pump switch that we discovered is quite literally a switch directly plugged into the female portion of the relay block thing (need to figure out a better way to do this so the car doesnt catch on fire), the bosche pump (stupid thing buzzes so loud after we flip the switch but not loud enough that I hear it with the car running) up in the engine bay, whatever mess of wires and filter thing is behind the wheel well, and I'm not sure what else fuel system wise.
That's a handy switch, I'd keep it if it's not obviously unsafe.
There should NOT be a pump in the engine bay. Are you sure you are not hearing the frequency valve buzzing (thing on the side of the Fuel Distributor)?
The cylindrical thing circlipped to the engine bay side of the front inner wheel well is a fuel filter.
The cylindrical thing with wires circlipped to the body next to the fuel tank at the rear wheel arch is the fuel pump.
If you actually have a fuel pump in the engine bay then you probably have no fuel filter and I also don't know what to say.
In its current state it does the things and my fuel gauge works, honestly kinda afraid to mess with it as I've seen some of the posts of struggles, but I need to figure out what and how this actually runs fuel because its funky
*edit* WUR is a warm up regulator. Learned a new acronym. I still gotta learn more about the lambda system yall speak of, but the bosche pump is the k-jet? I think? I'll have to carefully poke around and see if I can find some more information on the thing itself. I also have to locate where the WUR exists in my engine bay and follow where that goes
Read this for a high level overview of the different components, only 25 pages
https://cabby-info.com/files/fuel/KJetronicManual.pdf
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Fri Oct 24, 2025 10:47 pm Post subject: Re: Where do I go from here? |
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| Raize wrote: | | PopUpProject wrote: |
I have a fuel pump switch that we discovered is quite literally a switch directly plugged into the female portion of the relay block thing (need to figure out a better way to do this so the car doesnt catch on fire), the bosche pump (stupid thing buzzes so loud after we flip the switch but not loud enough that I hear it with the car running) up in the engine bay, whatever mess of wires and filter thing is behind the wheel well, and I'm not sure what else fuel system wise.
That's a handy switch, I'd keep it if it's not obviously unsafe.
There should NOT be a pump in the engine bay. Are you sure you are not hearing the frequency valve buzzing (thing on the side of the Fuel Distributor)?
The cylindrical thing circlipped to the engine bay side of the front inner wheel well is a fuel filter.
The cylindrical thing with wires circlipped to the body next to the fuel tank at the rear wheel arch is the fuel pump.
If you actually have a fuel pump in the engine bay then you probably have no fuel filter and I also don't know what to say.
In its current state it does the things and my fuel gauge works, honestly kinda afraid to mess with it as I've seen some of the posts of struggles, but I need to figure out what and how this actually runs fuel because its funky
*edit* WUR is a warm up regulator. Learned a new acronym. I still gotta learn more about the lambda system yall speak of, but the bosche pump is the k-jet? I think? I'll have to carefully poke around and see if I can find some more information on the thing itself. I also have to locate where the WUR exists in my engine bay and follow where that goes
Read this for a high level overview of the different components, only 25 pages
https://cabby-info.com/files/fuel/KJetronicManual.pdf
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Here's a video of the buzzing from when we first picked up the car https://drive.google.com/file/d/1DxSQnVAey_nAlW0ub6ar7nI3vRulWv3-/view?usp=sharing It might be the fuel distributor? Its a bosche something
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Just trying my best to figure this out without total failure
Poppy the '82 924 Resurrection in Progress |
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Raize
Joined: 18 Sep 2013
Posts: 411
Location: Scotland
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| Posted: Fri Oct 24, 2025 11:23 pm Post subject: |
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Yeah, that is the fuel distributor.
You might have frequency valve bolted to intake manifold as shown here, those things buzz if they are working.
Images just don’t work on this board… and image hosting is virtually banned in the UK now, oh well. |
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PopUpProject
Joined: 06 Aug 2025
Posts: 78
Location: NE Ohio
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| Posted: Sat Oct 25, 2025 2:09 am Post subject: |
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| Raize wrote: | Yeah, that is the fuel distributor.
You might have frequency valve bolted to intake manifold as shown here, those things buzz if they are working.
Images just don’t work on this board… and image hosting is virtually banned in the UK now, oh well. |
Yeah I can't see the image and I haven't been able to figure out how to embed images in here so I've just made a google drive that I use to send yall photos for help.
But I'll have to take a look and see if I see anything bolted to the intake manifold, and see what else I discover from around the distributor
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Just trying my best to figure this out without total failure
Poppy the '82 924 Resurrection in Progress |
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