Exhaust leak ar the turbo

[dunc]

See the pics, are there gaskets for these areas? Not 100% sure but think they might both be leaking, one of them certainly is. If it's just a case of replacing the gaskets I'd be happy enough with that

Had a search online but any search term with 944, turbo and gasket just brings up a load of head gasket info LOL

This is a pic looking up from under the car towards the turbo by the way!

Cheers,

Dunc.

 

[T3rra]

Any job in that area is almost turbo removal, then there's loads off while your in there jobs. Aos seals been one often missed.

 

[Frenchy]

Crush rings, yeah just whip the turbo off, TBH it will be a pig and you WILL snap studs so get a good stud extractor kit, sorry to quote bad news.

 

[944Scott]

When I fitted my three inch outlet pipe It came with copper gaskets, you could buy an offcut from e bay and make some.

 

[T3rra]

Maybe able to nip it up or cover with some sort off exhaust paste on the out side?

 

[ChasR]

I reckon that is a crack in the weld myself on the exhaust. For your sake I hope it is not, but looking at where the soot has gathered...

 

[dunc]

Thanks guys,

So is it possible to remove the exhaust with the turbo in place and do it that way? Then I could inspect that for cracks and replace the gaskets when I refit.

Removing the turbo does sound like a nightmare as it's tucked away from sight (especially from the top).

Cheers,

Dunc.

 

[TTM]

The weld has definitely cracked. They always do on the exhaust manifolds and cross pipe.

Yes you can remove the cross pipe without removing the turbo, and have it rewelded on the outside instead of the inside as done by the factory.

You may also have reweld the exhaust manifold flanges on the outside in the same fashion to prevent possible future cracking there as well.

 

[George Elliott]

you can remove the cross pipe without removing the turbo,

This would save a lot of work. do the weld repair, clean the ring grooves, new crush rings. job done.
Looking at the images, I'm not sure of the top right bolt.

George
944t

 

[dunc]

Got both the pipes off now. For anyone interested you can remove the exhaust and x-over pipes (just) without removing the turbo but the fact is by the time you get there you're only the oil feed and drain bolts away from taking the turbo out anyway.

The x-over pipe flange needed completely welded but the exhaust flange was only leaking due to a slack stud on the turbo. New stud and gasket for that side will be fine.

Any hints for removing the gaskets? They look like they're actually part of the flanges they've been there so long!

Cheers,

Dunc.

 

[George Elliott]

I take my hat of to you []

to remove the rings, a centre punch, a tiny drill, and great care not to damage the groove, and break the ring. Use a masonry (hardened) nail ground to a chisel like shape to lift the ring out of the groove.

Good luck

George
944t

 

[Frenchy]

A Dremmel helped me out, once you get a chunk lifted it will start to come away, keep your hands out as they are sharp and you will bleed ! never saw one come out in a one, usually half a dozen bits, persevere and you will get there.........................been there !

 

[dunc]

Cheers lads taking your good advice into account I got the seals removed. A vice, centre punch and drill got the job done []

Ordered new studs and locking nuts all round and will be ordering new gaskets from porsche today, fingers crossed they've got good delivery times

Cheers,

Dunc.

 

[dunc]

Everything's back together now and was hunky dorey, took it for a 100 mile but when I got home it wouldn't idle at all. It revs through the rev range but isn't very powerful.

I think it's got to be a leak between the AFM and the throttle butterfly, had a look for anything obvious last night but was just constantly burning my hands on things, going to have another go tonight.

Any common ones I can look at to start with?

Cheers,

Dunc.

 

[944 man]

An airline used to pressurise the inlet will help immensely.

 

[dunc]

Agreed should really sort out a proper test at some point, found the problem on further inspection predictably it was a pipe before the throttle butterflywhere a clamp must have been slack and popped off.

All sorted, MOT time next!

Cheers,

Dunc.

 

[George Elliott]

Hmmmmmm

Inlet Gaskets x4 to cyl head

ISV Port Line into Manifold
1/2" Line Hose beside it
Banjo and multiple vac lines to the left of ISV

Thats the Manifold

Jubilee on Turbo cold side outlet
Jubilee from outlet hose to hard pipe
Hard pipe banjo and seal washers
Jubilee to I/C inlet x2 (make sure the rubber sleeve is seated correctly
Jubilee on I/C outlet to hard pipe x2 (make sure the rubber sleeve is seated correctly)
Dump valve (check its not leaking air)
Crankcase AOS breather line to Hard pipe
Throttle body Rubber Jubilee x2 (check location on TB is seated)

Thats the KKK to manifold

Is the waste gate shut properly?
Are the vac lines to the heater connected properly
Is the crossover seated nicely, new crush rings, torqued evenly?
Waste gate flanged feed pipe seated and clamped secure
Dump valve vac line in the right place?

Airline is a good idea, but dont blow the seals out of the turbo with 6 Bar [8|]
The leak should be quite evident at 10psi

Good luck
George
944t

 

[dunc]

Thanks George,

Cracking list to keep for future but think we posted at similar times (see above).

Cheers,

Dunc.