924Board.org

[Eric P]

Hi everyone! I'm a bit new to the forums (My first post!) Hopefully I can be as helpful as you guys have been in the past month. You've helped me get my 924 running and driveable.

Some background: about a month ago, I bought a non running 924. The car had been sitting for about 5 years according to the service records I got with it. The timing belt and plug wires had just been replaced about 3000 miles and 5 years ago. I assume the timing belt should be done again, but it still looks like new. I went through some common maintenance items to make sure everything was up to par. I changed the spark plugs, oil, fuel filter, air filter, fuel injectors (they were spraying lopsided once I got them spraying), fuel injector o-rings, misc. dry rotted boots and vacuum lines, turn signal switch, ignition lock (matching keys now!!), and a few other small items.

I have however run into a small snag. When I got the car, the fuel distribution system was not working. When the pump was turned on, 3 of the 4 fuel injectors started spraying full bore. This didn't change whether the fuel distributor piston was up or down.

After using a pressure gauge to diagnose the problem, I decided it was time to rebuild the fuel distributor. I pulled it off and tore it down completely. What I found were three of the 4 o-rings on the distributor bore were torn. I replaced all of the o-rings and the diaphragm, cleaned all of the powdered gas out of the ports, and ultrasonically cleaned everything before sealing it all back up.

To seal the diaphragm, my friend gave me a tube of some blue permatex gasket goo which said fuel resistant on the back. I don't know exactly what it was, but I found out the hard way that it definitely wasn't fuel resistant. The distributor worked but after about 10 min with fuel in it, gas was spraying everywhere. I read on here a bit and found an article which recommends Indian Head Shellac. I bought a bottle and after gooing it all up, realized that while indian head shellac may be gasoline resistant, it will not hold up to the ethanol that our government sees fit to dilute our sweet petrol with. I'm a couple days in with the indian head and the diaphragm is definitely weeping fuel.

I realize I need to rebuild this dizzy yet again, but would rather not do it a 4th time. Do any of you have a recommendation of what to use to seal this thing up? I bought a tube of "fuel resistant" permatex gasket goo, but the amazon reviews don't look very promising.

here: https://www.amazon.com/Permatex-85420-Permashield-Resistant-Dressing/product-reviews/B007VIGCJW/ref=cm_cr_dp_d_show_all_btm?ie=UTF8&reviewerType=avp_only_reviews&sortBy=recent

Am I better off with motoseal? Is there another sealant that may work better for this gas/ethanol mixture? It seems like most sealants only resist one chemical or the other, but not both.

I'll throw a couple photos of the car up here tonight if I can figure out how to get them off my camera and onto my computer. Thank you all for your help so far!
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1980 924 NA, US model
1987 924S, US model

[Ozzie]

I used nothing on the metal diaphragm, they a machined surfaces and do not require sealant
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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

[Tiny]

I rebuilt 2 fuel distributors and both times failed to get a seal
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*****1981 - 924 - Auto - London, UK******

[Schwami]

I've tried to rebuild them a few times using O rings from harbor freight and rebuild kits from the internet. Tried a few times with out and with Smurf poop(VERY THIN). I'm getting better at it, BUT I finally was frustrated enough with my own lack of knowledge, patience and desire to drive my dogleg 79, that I sent it to an internet re builder in Texas who has them rebuilt. $350 is a lot of money for this guy and the turnaround wasn't exactly quick, but the great startup, performance and piece of mind(warranty) that I got from this vendor was worth the time and money.
If there are others that are able to do the same job at a better price and faster service, I would like to know.
Please PM me
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1979 924 Diamant Zweischicht.
Serial # 9249201031
XG 309 543 engine code.
2012 Golf Sportwagon TDI

[Kenodog]

Over time the metal casting warp. You will need to lap or re-surface both sides before re-sealing and you will have no problems.





Me
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1979 Euro 931, Olive
1981 931, Sabine
1991 Ford Ranger XLT 4x4, Ricky
1996 Ford E-350 ex-FedEx Van
2014 Mazda CX-5 (Kinderwagon)
2019 KTM 790 Adventure
2024 KLX300
2024 KLX140