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Full Version: Ice Green 1.8 Rescue
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Chris914n6
Back story: Car was dropped off at Carl's Cool Cars in Las Vegas based on high recommendations. Their VW specialist rebuilt the motor, bolted it back into the car, then quit. Then Carl splits with the rent money leaving all the cars to be impounded. Owner Eric posts on the 914 FB page he needs a 914 mechanic, @Toast says she knows a guy, and now it sits in my driveway biggrin.gif

My job is to get it to good Daily Driver condition, which involves figuring out the mess left over (particularly the 1.8L FI) and the usual old car fixes. This is my first time working with 914 Ljet so I'm sure I'll be asking questions, plus we'll need some parts that were lost.

Parts needed: (will get longer as the days go by)
-stock 1.8 banana muffler, gaskets, nuts & bolts.
-OEM door stopper lever/bar/tie rod piece.
-both caps for the relay board plugs. Found


Custom Adds:
There are a few goodies on the list...
-914Rubber top dash pad


Problems needing solved:
Ran out of beer.


Hello good look'n
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Chris914n6
Day1: Took inventory, made a long todo list, and a quick bath.

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Goodnight sleep tight.
/Day1
914_7T3
The photos look like ice green metallic!
Chris914n6
QUOTE(914_7T3 @ Sep 18 2018, 10:43 PM) *

The photos look like ice green metallic!

Whew. We weren't sure of the name but the stamped paint code is L96M. 3 votes = title changed. beerchug.gif
euro911
QUOTE(Chris914n6 @ Sep 18 2018, 10:34 PM) *
... Carl splits with the rent money leaving all the cars to be impounded ...
That's fucked up slap.gif
djway
L Jet is actually pretty simple. There are online trouble shooting manuals from Bosch that take you step by step. Most of the parts you can test yourself other than the brain.
Have fun.
euro911
Yeah, everything you'll need to know is on Jeff Bowlsby's 'Tech Notebook' site ... http://bowlsby.net/914/Classic/TechNotebook.htm
rick 918-S
Great color. Makes me smile smile.gif
Chris H.
L96M (original color) is Marathon Blue. Also a great color!
914_7T3
QUOTE(Chris H. @ Sep 19 2018, 07:50 AM) *

L96M (original color) is Marathon Blue. Also a great color!



agree.gif

L96M is Marathon Blue, however your car appears to have been resprayed in Ice Green Metallic. Mystery Solved!
76-914
Ooooh, she's cute and looks unmolested. Can you bring her over one summer! happy11.gif stirthepot.gif
whitetwinturbo
ar15.gif ar15.gif ar15.gif = leaves with rent money = Loser

What a pretty car!

cheer.gif cheer.gif cheer.gif
Chris914n6
Day2: Short and messy

I picked something easy and practical for the short first work day... replace the broken pass outer door handle with the key matching set and clean & re-lube the latch.

Did you know the stud could break loose and spin? Well it does and it makes removing the lock nut impossible headbang.gif I started with drilling it like I do a rivet head - stopped making progress when it decided to just spin. Plan B was to slot it with a cut off wheel but wasn't enough meat to hold against the lock nut. So ended up braking off the cast aluminum bits and the stud just fell out.

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Now the messy part. The whole inside of the door is covered in a honey like goo. At first I thought is was spray glue for the plastic barrier but it's soft and not so sticky. You can see it covered in dirt on both the latch and the outer handle area. Purple degreaser barely touched it.

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Gummed up latches, the leading cause of broken door handles.

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So fellow Fourteeners, when you're told to take your time estimate and double it, this is why.

1 line item done. Adding clean out door drains to the list sad.gif
/Day2
billh1963
Is the gooey stuff some sort of rustproofing?
76-914
popcorn[1].gif
pete000
Nice color ! worth the effort to save it for sure !
DRPHIL914
QUOTE(Chris914n6 @ Sep 20 2018, 01:01 AM) *

Day2: Short and messy

I picked something easy and practical for the short first work day... replace the broken pass outer door handle with the key matching set and clean & re-lube the latch.

Did you know the stud could break loose and spin? Well it does and it makes removing the lock nut impossible headbang.gif I started with drilling it like I do a rivet head - stopped making progress when it decided to just spin. Plan B was to slot it with a cut off wheel but wasn't enough meat to hold against the lock nut. So ended up braking off the cast aluminum bits and the stud just fell out.

Now the messy part. The whole inside of the door is covered in a honey like goo. At first I thought is was spray glue for the plastic barrier but it's soft and not so sticky. You can see it covered in dirt on both the latch and the outer handle area. Purple degreaser barely touched it.

Gummed up latches, the leading cause of broken door handles.

So fellow Fourteeners, when you're told to take your time estimate and double it, this is why.

1 line item done. Adding clean out door drains to the list sad.gif
/Day2



Brake cleaner works great on cleaning off all that gunked up grease on the lock mechanisms,
Do you see evidence of a color change? from the looks of the door it looks like ice green is the original color.
goop is most likely a rust proofing spray breaking down. if so there will be plugged holes used to spray in there andseal it back up, mine had that and the door was full of rust!,

Phil
mepstein
QUOTE(DRPHIL914 @ Sep 20 2018, 01:18 PM) *

QUOTE(Chris914n6 @ Sep 20 2018, 01:01 AM) *

Day2: Short and messy

I picked something easy and practical for the short first work day... replace the broken pass outer door handle with the key matching set and clean & re-lube the latch.

Did you know the stud could break loose and spin? Well it does and it makes removing the lock nut impossible headbang.gif I started with drilling it like I do a rivet head - stopped making progress when it decided to just spin. Plan B was to slot it with a cut off wheel but wasn't enough meat to hold against the lock nut. So ended up braking off the cast aluminum bits and the stud just fell out.


Now the messy part. The whole inside of the door is covered in a honey like goo. At first I thought is was spray glue for the plastic barrier but it's soft and not so sticky. You can see it covered in dirt on both the latch and the outer handle area. Purple degreaser barely touched it.

Gummed up latches, the leading cause of broken door handles.

So fellow Fourteeners, when you're told to take your time estimate and double it, this is why.

1 line item done. Adding clean out door drains to the list sad.gif
/Day2



Brake cleaner works great on cleaning off all that gunked up grease on the lock mechanisms,
Do you see evidence of a color change? from the looks of the door it looks like ice green is the original color.
goop is most likely a rust proofing spray breaking down. if so there will be plugged holes used to spray in there andseal it back up, mine had that and the door was full of rust!,

Phil

agree.gif they used to drill tons of holes and spray the Zeibart crap everywhere. What a mess.
euro911
Chris, are you sure of the original color (L96M)? Is the color on the interior of the doors blue?

Any telltale signs under the cowl area?

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At one point in time, (years ago), I thought I'd like to paint my '66 912 Ice Green.
dr914@autoatlanta.com
marathon is a great color on a 914 especially with chrome bumpers and Fuchs alloy wheels
douglastic
I think the colors are similar enough to be tricking some of you in photos.

I see 2 colors on this car.

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QUOTE(euro911 @ Sep 20 2018, 11:33 AM) *

Any telltale signs under the cowl area?
ClayPerrine
If you need help on the L-Jet, I would be happy to assist. I have worked on lots of L-Jet cars, and I have kept a 74 L-Jet car alive for 33 years.

I have boxes of L-Jet parts as well.

mgp4591
So far that looks to be in great shape Chris! Nice color and a good project car.... now see if you can get that one running sooner than your Porschissan! And I'll get off my slacker butt too... biggrin.gif
Chris914n6
QUOTE(douglastic @ Sep 20 2018, 11:52 AM) *

I think the colors are similar enough to be tricking some of you in photos.

I see 2 colors on this car.

QUOTE(euro911 @ Sep 20 2018, 11:33 AM) *

Any telltale signs under the cowl area?

Almost the whole car is resprayed. The air box wasn't removed but most of everything else was to change colors.

Contrast visible here.
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QUOTE(ClayPerrine @ Sep 20 2018, 12:38 PM) *

If you need help on the L-Jet, I would be happy to assist. I have worked on lots of L-Jet cars, and I have kept a 74 L-Jet car alive for 33 years.

I have boxes of L-Jet parts as well.

Thanks a ton. Between the wiring diagrams and tags and lose wires and odd part substitutes I'm under the assumption they were trying to fix a difficult problem. Owner drove it from Albuquerque to Vegas just fine, so I don't know the reason for the "trouble making shooting".

Pics of a complete installed system would be good, with components mounted where they are supposed to be and such. Also part testing specs.

Here is a glimpse of what I'm starting with.
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QUOTE(mgp4591 @ Sep 20 2018, 05:42 PM) *

So far that looks to be in great shape Chris! Nice color and a good project car.... now see if you can get that one running sooner than your Porschissan! And I'll get off my slacker butt too... biggrin.gif

Now that the temps are out of the teens... any day now piratenanner.gif
euro911
QUOTE(Chris914n6 @ Sep 20 2018, 10:17 PM) *
Now that the temps are out of the teens... any day now piratenanner.gif
Cool... pun intended poke.gif
914_7T3
QUOTE(douglastic @ Sep 20 2018, 11:52 AM) *

I think the colors are similar enough to be tricking some of you in photos.

I see 2 colors on this car.

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Here is a side by side comparo of the two colors!


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Tdskip
Enough on the colors already ( evilgrin.gif ) let's get her running!






I do love the current color, nice find.
Chris914n6
Day3: Tales of the DPO

Before I buttoned up the pass door I did testing with my collection of stinky clear fluids in tins and Acetone won as best goop cleaner. Good news is the drivers door latch didn't need much cleanup. Need an unbroken door stopper but I think I have one in my stash. Also aligned the window guide. So far every bolt I've touched in the doors has been just past finger tight. confused24.gif

Had a "since I was there" moment and.... well.... this is how 5 mins saves you 5 geez.
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So the pass seat was stuck forward and the handle on the wrong side. No biggie. Then I decided while I was there......
....I might as well put the drivers seat on the drivers side headbang.gif
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Got a bunch of stuff to do with the dash. Found another half ass moment. Vinyl yanked on til it tore and the middle 2 nuts for the dash frame removed, but the crunchy windshield seal still in place = no progress. Frame really needs to be popped free to wrap the vinyl so I made progress towards that until I got hungry. chowtime.gif
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Stereo for sale, period correct for a Chalon biggrin.gif

Wiring actually looks good - except for that one green jumper bridging power.
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pwnd rolleyes.gif
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/Day3
ottox914
Send them weekly updates. And invoices. It might be awhile.

Good on you for bringing another one back.
Chris914n6
Day 4: 5 out of 6 locks agree...

... that Ice Green 914 is the place to be. The trunk lock turned into a can of worms and will depend on if I have any hours left in the budget.

Not much interesting today. Got the dash frame free. 3 more locks changed out. Plugged in a battery and dived into the wiring, particularly the funny acting console gauges.

Found my bag of door stoppers - all broken, which makes sense that I would keep the working ones in the doors. (need one)

I have a feeling I've entered virgin territory piratenanner.gif

Foam piece between the shaft and lock cylinder. First one I've seen.
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Not sure if this is correct. I thought the pad went between the strap and the tank to prevent rubbing a hole?
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The spring was half hanging, so if you've never seen it, this is how it goes so that it doesn't bind. Do the top first, then the bottom one can be worked in with just fingers.
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Tomorrow I'm going to that place where things stand still to get my picture put on a new piece of plastic, then running errands after, so not likely to get anything done.

/Day 4
Chris914n6
Day 5: Gremlins a go go

Traced the gremlins back to a burned out blower relay and headlight switch, and a loose wire on the wiper motor.
Since HL switches are NLA I elected to fit this one. The nub that powers the headlight relay wore off (no light) so I soldered a new nub then swapped that contact plate with a single spring to lessen the wear. Should be good for a while. Also got the console gauges sorted.
I was so pleased it didn't take long to remedy the chassis wiring that I did a happy dance piratenanner.gif piratenanner.gif then some overdue yard work.

Top left if you can see it. Hole where a nub used to be.
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/Day 5
Chris914n6
Day 6+: You Look Dashing

Had a few weather delays and a rainy day house project interrupt progress.

Definitely easier to fit and glue the dash vinyl with the frame fully removed but it got done in car. Didn't want to mess with the blower controls which of course prohibits the frame from moving too much.
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New 914Rubber dash pad. Had to make a mod. The plastic retainers are much longer than the originals, which made installation in car impossible.
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Easily remedied by cutting all the fronts and the 2 behind the gauges to 2 nuts or ~13mm. Now I can insert top first then slide the front back into place.
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You will notice the gauge shroud 'peaks'. This is likely because the pad was sitting on top of the steering wheel for an unknown amount of time before I got it. It's deformed but I'm hoping it will flatten out on it's own in time.
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Plus a few things not pic worthy, unless you want to see the new wart huh.gif
/Day6+

Pretty much done with Phase 1
Phase 2 - Drivetrain biggrin.gif
second wind
That is a bitchin' color but it ain't L96M......just sayin'......
gg
Chris914n6
Day 7: Roll me under (Pretty sure that's a song lyric stuck in my head) aktion035.gif

Pressure washed the underside. Unfortunately that did a number on my neck and I had to take a few off. But I did get the drivetrain out today and blew off a years worth of desert dust. Found the 2 missing connector covers smile.gif

Way too many finger tight bolts confused24.gif

One of my 'tricks'. The all thread keeps it from going down hill on the sloped driveway and keeps it lined up during install. Also makes it possible to R&R with just one jack though it's slow.
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/Day 7
Dave_Darling
QUOTE(Chris914n6 @ Sep 20 2018, 10:17 PM) *

Pics of a complete installed ... [L-jet] system would be good, with components mounted where they are supposed to be and such. Also part testing specs.


The Haynes manual has specs and layout of an early 1.8, believe it or not. The specs are a bit scattered throughout the FI chapter, though.

--DD
Chris914n6
Day 8: Testing One Two Three Fuch

Did a pin-by-pin check of the ECU harness and it's all good. Just need to tie off the bare ends to the Altitude Compensator.

Component checking is mixed.
AAR - had a reading then nothing. Haven't power tested it yet. Failed.

AFM - Left 2 pins on/off. Middle 2 pins 400 ohm fixed. Right 2 pins 160-400 ohm but erratic. Shouldn't something be progressive as the flap moves?

Dual Relay - full of water at some point. First will clean then power test.

Injectors - Still need to clean and flow test.

All the rest test good.

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Day 8 not over yet.
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