Turbo maintenance/refurb

Gazc2 · 31 Aug 2019

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

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)

NickHappy · 31 Aug 2019

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:

Gazc2 · 31 Aug 2019

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

https://www.maxspeed-motorsports.co...HP_70mm_Turbo_Back_Exhaust_System_w/Tips.html

:thumb:

NickHappy · 31 Aug 2019

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

https://www.maxspeed-motorsports.co...HP_70mm_Turbo_Back_Exhaust_System_w/Tips.html

:thumb:

Looking forward to seeing the finished article

keendean · 1 Sep 2019

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
:thumb:

Gazc2 · 1 Sep 2019

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-gl...e=STRK:MEBIDX:IT&_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

Gazc2 · 2 Sep 2019

Turbo to cat studs ?

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

Gazc2 · 2 Sep 2019

Managed to find these, not sure if they will fit ? can the stud screw through the turbo housing ?

easternjets · 2 Sep 2019

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!

Gazc2 · 2 Sep 2019

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.

easternjets · 3 Sep 2019

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?

Gazc2 · 3 Sep 2019

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

darkhorse · 5 Sep 2019

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

Gazc2 · 5 Sep 2019

I wont be back at them until this weekend, I will keep you posted :thumb:

easternjets · 5 Sep 2019

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!

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