1998 996 C2

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ATM

Original Poster:

18,313 posts

220 months

Sunday 13th August 2023
quotequote all
So I made a start on the starter job. Idea is to remove and also refurb and then refit. I think I might replace the y cable also.

Alternator is still off the car waiting for the starter to be done first. I'm hoping that having the alternator out will give me better access to the starter and y cable.

I got the throttle body off in 5 minutes. Then I quickly ground to a halt with the jubilee clips. Hopefully you can see why.






ATM

Original Poster:

18,313 posts

220 months

Monday 14th August 2023
quotequote all
The PO did rebuild the engine at home. So I'm assuming he fitted these jubilee clips with the engine out and that's why the adjusters are on the wrong side. Short of dropping the engine I think I'm going to have to cut them off with a dremel or something.

ATM

Original Poster:

18,313 posts

220 months

Monday 14th August 2023
quotequote all
Ha Ha

You can actually see they're fitted back to front in these pics from my first post which I got from him of the rebuild.






ATM

Original Poster:

18,313 posts

220 months

Friday 18th August 2023
quotequote all
Success with the dremel even with the restricted access












ATM

Original Poster:

18,313 posts

220 months

Friday 18th August 2023
quotequote all







ATM

Original Poster:

18,313 posts

220 months

Friday 18th August 2023
quotequote all

ATM

Original Poster:

18,313 posts

220 months

Friday 18th August 2023
quotequote all
nebpor said:
Good luck with the Y cable - my mechanic was cursing me biggrin
Why?

I got the old one off easily so fitting the new one can't be too tricky

ATM

Original Poster:

18,313 posts

220 months

Friday 18th August 2023
quotequote all
ATM said:
Not sure if I could test this because seems wasteful to just replace blind

ATM

Original Poster:

18,313 posts

220 months

Friday 18th August 2023
quotequote all
ATM said:
This was the old starter. You can make out the 996 part number. So I'd guess it was the original.

ATM

Original Poster:

18,313 posts

220 months

Saturday 19th August 2023
quotequote all
shalmaneser said:
nebpor said:
Good luck with the Y cable - my mechanic was cursing me biggrin
When I did mine it really wasn't that bad!
Notpoor has a 996tt. Maybe they are trickier.

ATM

Original Poster:

18,313 posts

220 months

Tuesday 5th September 2023
quotequote all
ATM said:
New Y cable

They look identical. New one is soft and bendy. Old one is stiff as a teenager's todger first thing in the morning.

I didn't see that clip [midway of the longer section] when I removed my old one. Anyone know where it should clip?


ATM

Original Poster:

18,313 posts

220 months

Tuesday 5th September 2023
quotequote all
So I spent some time on the car today trying to get it back together.

Y cable fitted - this probably took 30 seconds max. So if anyone is considering it I will say it is easy once the starter and alternator are off the car.

The trickiest part for me was the plenum t piece and its jubilee clips. Anyone who is not interested can just forward past this next paragraph to the final one. The starter went on easy. I had to refer to some pics to figure out which bit of the y cable bolted to it. The alternator was really easy too. Refitting the drive belt is a piece of cake.

At first I forgot I needed new jubilee clips. The first 4 I bought were too small, they were 80 to 100mm. So I bought some which were 90 to 120 I think. This presented a problem of the extra threaded section once through the clasp got in the way or interfered with other stuff. Just pushing the plenum into position isn't obvious. I kept wiggling until I thought it was right. Then I had problems with the breather type hose fitting [top left in pic 2] interfering with the jubilee clip and I had to reposition the jubilee. Then when I tried to refit the throttle body I realised that the t piece needed to be rotated some more. So yes this all took way longer than I thought it should.

So when I ran out of time or light all that remains is refitting the throttle cable and then the air box.





ATM

Original Poster:

18,313 posts

220 months

Wednesday 6th September 2023
quotequote all
Taking a fresh look today. Got the accelerator cable on. Next is airbox.

Wait

What's this plug for?

Anyone know?


ATM

Original Poster:

18,313 posts

220 months

Wednesday 6th September 2023
quotequote all
ATM said:
Taking a fresh look today. Got the accelerator cable on. Next is airbox.

Wait

What's this plug for?

Anyone know?

Panic over

It connects to this solenoid - I think that's what its called

I can confirm the engine now runs

So I have replaced -

Alternator
Starter
Y cable

And it has been in pieces since the beginning of July so it was lingering a bit but now the engine electrical bits are done


ATM

Original Poster:

18,313 posts

220 months

Wednesday 6th September 2023
quotequote all
ATM said:
I can confirm the engine now runs
Yes

ATM

Original Poster:

18,313 posts

220 months

Wednesday 6th September 2023
quotequote all
So I have had these zenon converted headlamps for 5 years but never used them because one of the clips is broke and therefore the light flaps around inside

My bodge is to use this rubber band to keep tension on the light unit and stop it wobbling around

Now I just need to secure it to something and see if it holds




ATM

Original Poster:

18,313 posts

220 months

Wednesday 6th September 2023
quotequote all
So for now I am using this claw like bracket which holds the cover in position.

If anyone has fitted lights like this before with the boxes and gubbins hanging out the back do these need securing or can they flap around?

Also where the wires go through the backing plate which has been cut or drilled to provide a hole does this need to be quite water tight or not that important?

Thanks....






ATM

Original Poster:

18,313 posts

220 months

Wednesday 6th September 2023
quotequote all
So I fitted these lights to my other working 996 to test them out. I suppose therefore I should post this in the other cars blog but I can't be arsssed.

So fitting was a bit finickety. I did tape the gubbins to the back of the light using gaffer tape - pic 2. Took a few trial and error goes to get the bracket to click them in solidly.

Then when I closed the carbon bonnet - pic 4 - which doesn't fit well, it pressed on the driver side light and pushed it out slightly. Not sure if I should do anything about this or just pretend I don't know.

Tested the lights on the drive.

Side lights do not work.
Dipped zenons work both sides.
Main beam only works on passenger side - pic 5

Now I'm waiting for it to get dark so I can probably see the adjustment is all over the place just to really hammer it home that I shouldn't have bothered really.

Pics....











ATM

Original Poster:

18,313 posts

220 months

Thursday 7th September 2023
quotequote all
I did some testing last night with the zenon converted lights on the other car. Here are a couple of snaps. The good news is yes the light thrown is much much better than the truly dreadful light fron the original headlamps. Hopefully that should be obvious or a given.

In summary the driver side wasn't fully working at first and then got dislodged while driving / braking and it all went off. So I have had a fiddle with this today and it seems better now. I will try more testing later in the dark and report back or update the other thread for the other car maybe.






Back to this car ..

So the nicer lights fron my working 996 are now on and obviously look much better.

I am nearly there now with my list of jobs from the previous MOT failure.

Horn not working - probably an earth issue with the momo wheel boss

Rear brake binding a bit hopefully just from lack of use




ATM

Original Poster:

18,313 posts

220 months

Friday 8th September 2023
quotequote all
ATM said:
Rear exhaust silencer flexi disconnected so exhaust blowing and could not be emissions tested

Driver door exterior handle inoperative

Headlamps clouded up

Rear Driver side caliper binding a bit - probably due to lack of use and disc all covered in rust

Horn not working - it is a bit intermittent so assume dodgy connection in the momo adapter
To Do
Horn
Rear exhaust flexi - hopefully first thing in morning before it gets too hot for rolling around under a car wearing overalls

Done
Freed up Rear brake - hopefully - untested
Headlamps changed - untested but were fine on donor vehicle
Locks or door catches changed both sides - working fine

Other
New Starter
New Y cable
Refurbished Alternator

Yes that MOT failure says November 2022