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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Sat Aug 31, 2019 6:25 pm    Post subject: Turbo maintenance/refurb Reply with quote

So the turbo failed its MOT on the horn not working now this is a pain of a job to get both horns out so decided to stick it on sorn and make a start to some of the jobs on my list which are as follows

Fit my sports exhaust
seized passenger side actuator to fix
New disc & pads on the rear
Fit lowering springs
replace all fluids on gearbox and diffs
Ac condensors and center radiator replacement

Fit my aerokit including rear spoiler front splitter and GT2/GTS side skirts get the front end sprayed as part of this.

so made a start today and tackled the job I have been putting off for 2 years the corroded/chocolate nuts on the exhaust/turbo now after faffing about for about an hour and a half with the first one with the Dremel and chisel,d the best way for me was to cut through the side of the corroded nut and through the washer with a Dremel then chisel the washer out which releases the corroded blob and it turned of the thread no bother so used this on the other 3 and had them off in less than an hour.

That just leaves the top ones Surprised I am going to remove the intercoolers to clean them up which will also give better access the nuts on the manifold are also toast but easy to get to so they will also be replaced I don't intend doing the manifold to head bolts (yet)
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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NickHappy
Nürburgring


Joined: 27 Apr 2014
Posts: 455
Location: W.Sussex


PostPosted: Sat Aug 31, 2019 8:41 pm    Post subject: Reply with quote

Good Work and good pictures - looks
Like some of my posts - what type of Exhaust are you putting on then??

Please keep the pics and updates coming as following with interest Thumb
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997 turbo Manual.
996 turbo Manual. ex.
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Sat Aug 31, 2019 9:13 pm    Post subject: Reply with quote

Nick I have had this lying in the garage for three years not overly loud just a bit gruff

https://www.maxspeed-motorsports.com/store/p121/Porsche_997_Turbo_NHP_70mm_Turbo_Back_Exhaust_System_w%2FTips.html

Thumb
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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NickHappy
Nürburgring


Joined: 27 Apr 2014
Posts: 455
Location: W.Sussex


PostPosted: Sat Aug 31, 2019 9:18 pm    Post subject: Reply with quote

Gazc2 wrote:
Nick I have had this lying in the garage for three years not overly loud just a bit gruff

https://www.maxspeed-motorsports.com/store/p121/Porsche_997_Turbo_NHP_70mm_Turbo_Back_Exhaust_System_w%2FTips.html

Thumb


Looking forward to seeing the finished article Very Happy
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996 turbo Manual. ex.
 
  
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keendean
Monza


Joined: 11 Aug 2011
Posts: 159
Location: Cambs


PostPosted: Sun Sep 01, 2019 8:08 am    Post subject: Reply with quote

Look forward to seeing the GTS side skirts, I was contemplating them too, but maintenance came first. Did you buy from OPC direct?
I’ve had both condensers replaced, but the front rad is original, I’m
assuming they perish over time? I replaced my exhaust with a Kline and sports cats with a mate on a ramp, well worth it. The turbos now spool nicely, just needs a 9e map one day. Good luck
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Sun Sep 01, 2019 6:02 pm    Post subject: Reply with quote

I have still to purchase the side skirts and have spoken to OPC £354 + vat last time I asked.

I have printed off a few guides to aid me along with some of the work if you have a look over on Rennlist for "The Rock" he has compiled some excellent guides.

so I removed the pass intercooler today and was interested to see what debris these accumulate which was surprisingly little mandatory birds feather and a few leaves.

I had a look at my actuator which it turned out was not seized and was moving freely up and down,small point here if your lying under the car and testing these the drivers side pushes up the way and the pass side pushes down from the top (Or pulls) where it is seized and is common is the push fit ball joint on the connecting arm and I will probably change these for new ones once I get them off and give them a liberal coating of grease

this is the grease one tube will do the whole fleet of turbos in the uk

https://www.ebay.co.uk/itm/fuchs-gleitmo-wsp-5040-high-performance-grease-paste-porsche-actuators-997-911/401551332070?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

pictures not great but you can just make out the top of the rod circled, there was a good article in 911 Porsche world with sid from Porsche torque fixing these think it was Jan 18

link to the article below didn't realise you need to do an adapt/reset once you free off the rods,diagnostic will tell you if they are operating properly

https://www.pressreader.com/uk/911-porsche-world/20180105/283205853646256
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Mon Sep 02, 2019 11:22 am    Post subject: Turbo to cat studs ? Reply with quote

I know there are numerous threads on this subject and not sure I am any clearer after reading them however think the consensous is titanium is the way to go -poppabang is no longer doing the kits so can anyone give me an idea on suppliers ?

I am looking for 14 studs (4 on cat and 3 on manifold)

Pet says the stud is M8 x 22 think the ones PPB was suppling were 30mm ?

supplier for the K nuts is Merlin

https://www.merlinmotorsport.co.uk/p/k-nut-6-point-m8-x-1-25-k-nut-m8


and any recommendations on a decent stud extractor appreciated
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Mon Sep 02, 2019 12:10 pm    Post subject: Reply with quote

Managed to find these, not sure if they will fit ? can the stud screw through the turbo housing ?
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2112
Location: Darlington


PostPosted: Mon Sep 02, 2019 1:05 pm    Post subject: Reply with quote

I did mine and hunted round for Titanium but as I was selling the car I just put the original studs back in.
I found it was the nuts that deteriorated not the studs them selves, so it might be worth just getting the K nuts in Titanium. Again I tried to find them but in the end went to Screwfix and bought a bag of a 100 nickel coated for about £10.
Talking about this brings back horrible memories of trying to get those flippin corroded nuts off, think it took most of an afternoon to do!
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Mon Sep 02, 2019 2:29 pm    Post subject: Reply with quote

Nick The threads are a bit knarly on a couple that I have removed so far so think I will end up changing the studs on the Turbo/cat the manifold/turbo ones don't look too bad so will hopefully just end up changing the nuts.

think those studs will be fine if you can screw them through the turbo as my new cats will have clearance for a slightly longer stud on that side.
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2112
Location: Darlington


PostPosted: Tue Sep 03, 2019 9:08 am    Post subject: Reply with quote

From memory and looking at pics i'm pretty sure the studs do go all the way through but could you not grind them down to the same length?
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Tue Sep 03, 2019 10:05 am    Post subject: Reply with quote

I think either option is doable not worried if they stick through the back, I need to measure the distance across the flange/turbo to see if the 35mm (which I am assuming are 17mm from the middle) is long enough. the original studs have different length threads
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 141
Location: under the car


PostPosted: Thu Sep 05, 2019 8:16 am    Post subject: Reply with quote

Nice work Gaz, horrible job! Mine ended up having a stud snap by the garage who then drilled it out and fitted a nut and bolt. Not a very clever idea as it was a total pain to get off when I ended up doing the car myself. May be quite a test to get them out though. Hows it coming on?

My new turbos have new ones on so it was only every going to be a stop gap for me. As easternjets says, if you can dremel the old nuts off and clean up the threads? would be way easier, oh and use lots of heat! I had a total nightmare getting the turbo exhaust gas sensors out of my turbos so I could remove them. Just hope you don't have to do that bit, if they were anything like mine it was a total mare to free them
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Thu Sep 05, 2019 9:12 am    Post subject: Reply with quote

I wont be back at them until this weekend, I will keep you posted Thumb
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 
  
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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2112
Location: Darlington


PostPosted: Thu Sep 05, 2019 10:36 am    Post subject: Reply with quote

Hi Gaz the threads are uneven in length due to one side being screwed directly into to the turbo unit and the other, with the smooth part, being the thread that the K nuts go onto.
I know this sounds rough but I did split a few of the nuts with a v sharp chisel as they were so far gone I couldn't even get vice grips onto them! Use plenty of release fluid as well, especially when you just get them to move a bit.
Attached is a picture of my nuts and studs once removed!
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 



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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Sun Sep 08, 2019 7:00 pm    Post subject: Reply with quote

So a fairly succesfull weekend with all the nuts removed from both the manifolds and turbos, 1 stud came out the pass side manifold and all three on the drivers side so these will all be replaced not a problem you would rather they came out than snapped ,as Nick mentioned the studs are not the problem I am going to run a die up all the studs on the turbos to clean all the remnants from the nuts and see how they look.

It is a bit of an eyeopner how bad some of the nuts were don't think some of them would be keeping a tight seal before much longer and the exhaust is also beginning to look worse for wear 12 years old now if you haven't checked these I would have a look.

There is no doubt its a pain of a job that takes a while but slow and steady and its all doable

so plan is to get some studs and manifold gasket ordered up and now the exhaust is off see if the 02 sensors will come out (wishfull thinking)

some pics of old studs,new nuts fitted to manifold and the cuttings Thumb
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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easternjets
Watkins Glen


Joined: 29 Apr 2016
Posts: 2112
Location: Darlington


PostPosted: Sun Sep 08, 2019 10:30 pm    Post subject: Reply with quote

Good job Gaz glad to see you've put some copper grease on, it might not be the magic bullet but it gives you a chance of getting them off.

Pity they didn't make the nuts out of the same material the studs are made from.
_________________
997 Turbo Gen 2
997 Turbo Tiptronic S
Porsche 968 Coupe 1992
Porsche 928 S4
Porsche 911 3.2 Carrera 1985
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Fri Sep 13, 2019 4:11 pm    Post subject: Reply with quote

The new studs and manifold gasket arrived so set about installation and running a die up all the studs on the turbo`s, good news is they all cleaned up peachy and now cleaned and ready for the exhaust to go on so delighted to dodge any bullets on this exercise

(think I will ask the mods to merge this with my refurb thread)
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2016
Location: Perthshire


PostPosted: Fri Sep 13, 2019 5:18 pm    Post subject: Reply with quote

Bit of an oil weep going on at the back right hand corner not sure if its coming from that big coupling so will give the whole area a clean and see where its coming from.
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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darkhorse
Silverstone


Joined: 24 Feb 2019
Posts: 141
Location: under the car


PostPosted: Sun Sep 15, 2019 3:34 pm    Post subject: Reply with quote

Looks like it could be the sealing washer on the compression fitting that feeds the oil return, I would clean it all down and run it and see like you say*
Mine wasn't leaking but I replaced that pipe as it was looking a bit worse for wear at the metal crimp joints. What I will say is that it was a total b**ch to get off; applying heat in that area is not a good idea as it will perish the orings in pump behind maybe. Although I tried Map heat onto the nut, there is oil in there that you cant remove as it doesnt fully drain so its not a great plan and you cant get much heat on it..

In the end the entire compression piece unscrewed from the engine, but joint from pipe nut to the start of the coupler would not undo no matter what i tried. And you cant undo the nut from the head unless the nut will spin on the end of the pipe.
Having said that; if I hadnt had the engine out and stripped I would have tried more things.

So tackle that with caution! I had to cut the pipe at each side of the engine and then removed the fittings, cleaned it all up and fitted a new one (£500 worth of pipe) and new couplers and sealing washers.

Is the other side the same? Refitting the pipe would require a lot of work I think, at minimum engine dropped a bit, remove rear mount bracket, undo pipe clip from bottom of main front coolant manifold, remove turbo on bank 2 (a whole rats nest on its own.) and then thread the new up to the oil tank. It may not need turbo off, but the turbo pipes would make it a pain as the oil tank feed side of it is chunky.

Last edited by darkhorse on Sun Sep 15, 2019 4:00 pm; edited 1 time in total
 
  
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