January 13, 2002

Recommended 993 toolkit




Here are the parts that I believe should be in the 993 toolkit.
I had the misfortune of my car breaking an alternator belt at the
track and finding that my toolkit was missing tools.

And of the tools that remained, they were bascially crap. For
example, the wrenches were of such inferior quality, they started
flexing after the slightest bit of pressure was applied.

During the time that I replaced my alternator belt "in the field",
I was fortuante to be with somebody with good tools. Even then, we had
to apply significant muscle to many of the bolts. There is absolutely
no possible way that I could have completed my repairs using only the 993
toolkit. Using the included 993 toolkit to service your car could be
hazardous to your personal safety.

Here are a list of things that I believe allow you to make simple roadside
repairs. This is based on my experience of replacing the alternator belt and
changing tires. I'll add to this list as my experience grows.

The items in the above picture are:


  1. 8 mm combination wrench
  2. 10 mm combination wrench
  3. 13 mm combination wrench
  4. 17 mm combination wrench

    Note: All the above wrenches are commonly available as a set.
  5. 24 mm combination wrench

    Used to loosen the alternator nut if you are changing your alternator/fan belts.

    Note: This wrench is not usually part of a set and should be bought seperately.
  6. Folding Hex Key Set. This piece is not required, but there are a lot of hex bolts and this may come in handy.
  7. 6 mm 3/8" drive bit socket

    Used to remove the 3 intercooler bolts from the engine.
  8. 5 mm 3/8" drive bit socket

    Used to remove the 3 bolts from the fan belt pulley.

    Note: The above two items are also available as part of a set here.
  9. Oops, jumped a number in my picture above. :)
  10. 3" 3/8 drive extension
  11. 3/8" drive ratchet
  12. 1/2" drive 19 MM 6 point ratchet head

    Used to remove the wheel lug nuts
  13. 1/2" drive 17 MM 6 point ratchet head

    Note: The picture shows a 12 point socket, but purchase the 6 point socket instead. It is stronger.
  14. 1/2" drive 6" extension
  15. 1/2" drive flex handle

    Note: The picture above is a 1/2" drive ratchet. Either the flex handle or ratchet is fine.
  16. Tow hook, part of the standard 993 toolkit
  17. Unknown 8 mm tool, part of the standard 993 toolkit
  18. Unknown tool with 5 mm hex on one end, part of the standard 993 toolkit
  19. Universal jointed spark plug tool, part of the standard 993 toolkit
  20. Right angle screwdriver tool, part of the standard 993 toolkit
  21. 12 point allen head, Porsche Part #999 571 052 02. [Pic]

    Note: This tool is commonly missing from the 993 toolkits and is absolutely necessary to change the alternator belt.

    If you want to find out Robin's order with a stripped alternator shaft, look here.
  22. 4 in 1 screwdriver. Get a decent one from any hardware shop.
  23. Magnetic pickup tool. This is optional, but definately comes in handy.
  24. A decent pair of pliers.

  25. In addition to those tools, I would also recommend the following:

  26. DME relay update used to fix intermittent starting problems. Porsche Part # 993.615.227.00

    Not all relays are defective. Here is more information here
  27. Extra fuses, 30 A, 25 A, and 15 A blade type fuses.
  28. Alternator belt, Porsche Part # 999 192 372 50. 9.5 mm X 757 mm

    Note: This is for 993 TT with the alternator pulley update applied. Normally aspirated may be different, please check your owner's manual.
  29. Fan belt, Porsche Part # 999 192 343 50. 9.5 mm X 760 mm

    Note: This is for a 993 TT, normally aspirated models may be different, please check your owner's manual.
  30. AC belt, Porsche Part # 999 192 363 50. 13 mm X 1085 mm

    Note: This is for a 993 TT, normally aspirated models may be different, please check your owner's manual.


When I prepare for long drives and track days, I take all of these tools with me just in case I
cannot get help in other ways. However, in everyday driving, I take a reduced set of tools, namely my AAA card. :D

Jeff

Email me




Posted by jchan at 12:07 PM

November 13, 2001

All 993 owners should know this!!!

Note: Posted by David Edwards (dwe8922@yahoo.com)

A while back, I had a problem of my car not starting. It would turn over, and not fire. After much searching, I narrowed it down to the DME relay. I bought a new one, and kept it in the car until the problem arose. It did today, and after I popped in the new relay, it worked fine.
I mentioned this in tangent on a thread already, but its worth mentioning again. Porsched used a relay with a 944. part # prefix well into the 993 run, and later replaced that part with part # 993.615.227.00. The 944. relay was found to be faulty. My hometown dealer says they replace the 944. relay on all the cars they service as a precaution. At $15 from Hendrick Porsche, its cheap insurance.

Posted by jchan at 12:19 PM
Hollow Spoke Debris Update

Hi All...

A while back, I wrote to the board about hearing some debris in my left front wheel. Here's the original posting: http://boards.rennlist.com/cgi-bin/993/993.pl?read=54640

I contacted a person here in the Bay Area who specializes in wheels ( Weideman's Wheels ) and he said that this was a common problem with hollow spoke wheels. He stated that the steel beads used to remove the paint commonly end up in the hollow spokes if the valve stem is not properly plugged up.

Well, he didn't find any steel beads in my rims, but instead, metal flakes!

Here's a picture of what came out of the wheel:


So, what do you guys think? I am leaning towards selling these wheels and getting a polished (not chromed) set of hollow spokes.

Anybody seen this before?

Posted by jchan at 12:19 PM
Alternator Pulley Update

I got all my belts changed and the alternator pulley update installed.
I had a question about the install though. In the TSB, it states that you do not need the outer alternator shaft spacer anymore. The one closest to the 24mm nut. But you still need to install the inner spacer, the one closest to the fan pulley.

For clarification, the spacers are the two things that go on the _outside_ of the pulley halves. They are quarter sized and rounded on the edge.

However, when we put the inner spacer and the updated pulley on, the fan belt angle was pretty severe, definately not straight relative to the fan belt. Additionally, the outer pulley would have been on the threads of the alternator shaft and not the smooth portion.

When we installed the pulley update without the inner spacer, the belt angle was perfect. It didn't really matter if the outer spacer was installed or not.

Has anybody else done the alternator update and can comment on this? Did Porsche screw up on their TSB documentation and switch the outer and inner spacer? Maybe I read the documentation wrong?

Also, Robin, here are the correct sizes for the belts for a TT that you can use to update your web site.

Fan 9.5 x 760
Alt 9.5 x 753 ( 9.5 x 757 with pulley update )
AC 13 x 1085


Jeff


ps, fyi, chiseling off a bolt was a great trick to get the flywheel pulley off when we stripped the bolts. Sounds scary, but it isn't. You just use a sharpened chisel and tap the side of the head of the bolt, a bit off center, so that it unscrews. The chisel should be at enought of an angle to dig into the head. It destroys the bolt, but gets it off quick! Expecially working in the tight confines of the TT, it was almost easier than using the socket wrench!

Posted by jchan at 12:17 PM
Transmission Fluid DIY

Just finished changing my transmission oil and it was pretty easy and my shifting action is much smoother.. It also gives me more peace of mind. There aren't any filters in the trans! Really the hardest part was jacking up the car onto 4 jack stands.
I used 4 quarts of Amsoil 75W90 syntethic oil. Interestingly, it was pretty difficult to find Mobil 1 gear oil, which was my first choice. I found mostly Amsoil and Redline in shops. This oil wins the more colorful prize. It was a light blue color.

The manufacturer recommends doing this change at 30K, but at 19K miles, my trans oil was pretty dark and murky. There were a few shavings on the magnetic plug, which I cleaned off. ( See pic below. )

Thanks to Robin for a wonderful DIY. It helped me tremendously. Here are a few tips for the first time DIY'er that would be helpful.

a) You may need to put blocks under the rear wheels while jacking up the front of the car. With the front already on jack stands, the jack has less clearance to get under the tail of the car. My car isn't lowered, but I needed the cinder blocks in the picture to get the jack under there. I used the rear engine jacking point without problem. The hockey puck trick worked great!

b) Definately use a 10 MM allen key socket. I had to purchase a 3/8" to 1/2" drive adapter to use a bigger ratchet handle. Those bolts are on pretty tight.

c) Robin's DIY recommends that you remove the filler plug first, which is a good idea. However, it makes more sense to just make sure that you can loosen both the filler and drain plugs. You don't have to remove them right there, otherwise, trans oil will start to flow out of the filler.

d) If you wait about 1/2 an hour for all the old transmission fluid to drain out, it will take all 4 quarts of the new fluid without spilling out of the filler tube. Just keeps things a bit cleaner. I liked the "oil bong" technique. It worked great. I used 7/8" tubing and shaved down the end a bit. I then screwed it into the filler plug. If I were to do it again, I would have purchased an extra quart of AMsOIL to run through the transmission case to flush out any extra impurities.

e) Also, you will have to take off the driver rear wheel. I ended up taking off both rear wheels, becuase I couldn't tell in Robin's picture which one to do.


Lifting the front of the car ( Hey, there's Suwipin in the background with his new C4s! )


Me working the jack:


Up on all 4 wheels:


Condition of the Transmission Drain Plug:


Another shot of the transmission drain plug:

Some oil traces:

Transmission oil ( this stuff is blue ):

Oil Bong:

Now that I have all the tools, if anybody in the Menlo Park area wants to change their transmission fluid, or do other DIY projects, you are welcome to use my house and tools.

The next step for me is to do an oil change and bleed the brakes!

Posted by jchan at 12:03 PM
DE versus AutoCross Events

I just got back from the pca autocross in dublin. I was hoping to get a better understanding of car control at the limit in a wide open area. This was the last pca autoX this year and it was held in dublin. Interesting enough, this was held at the sheriff's facility and there was a prision near by also.

My initial impressions were that the lot was pretty small. There were walls and a few light sanctions. The walls were the biggest problem, which really kept me from pushing my car as hard as I would have liked at an autoX. Of the time that I did have on the course, it was pretty fun. But time was my biggest complaint also. I got there about 10:30 and left at 4:30. I had had a total of less than 3 minutes of time on the course.

I guess I got spoiled with all the track time that Todd's events have. I think that I really could have learned a lot from autoX, but before you even get comfortable with the track, it's time to turn off and wait for a few hours... It was pretty frustrating. I met some other people there who were thinking that autoX was a good prelude to track events, but I dissuaded them. Definately, jump right in to track events.

Posted by jchan at 11:51 AM