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Wastegate removal
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bureau13  



Joined: 07 Sep 2017
Posts: 239
Location: South Florida

PostPosted: Sat Apr 04, 2020 9:34 am    Post subject: Wastegate removal Reply with quote

So while waiting for my clutch master and slave cylinders to arrive, I finally decided to remove the wastegate. Or, finally decided to try. Holy crap.

I've removed the J-pipe (easy) I've removed two nuts and two bolts (weird) from the other pipe, but the studs are still there so I haven't got that pipe off the car yet. My thought was I would just take the wastegate down but...that doesn't seem like the answer. Somewhere someone wrote to remove the exhaust. That didn't look necessary, except for the stud issue. Is this the reason people remove the whole exhaust? Or is there another reason.

My biggest problem after fiddling with it a bit, is I have no idea how to get a tool on the nuts that hold the wastegate in place by the bracket. There's just no room. I have a long flex-head ratchet, but once I do get it on the nut there's not enough room to move the handle to turn the nuts. How do you guys do this?!
_________________
-----------------------------------------
1982 931
1986.5 Silver 928S
2007 Hummer H3 (Daily Driver)

Past lives (I miss them all):
2004 RX-8 (Wrecked)
1993 RX-7 (Sold)
1987 RX-7 Turbo II (Sold)
1985 RX-7 GSL (Stolen)
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K-Roll931  



Joined: 08 Jul 2017
Posts: 64
Location: Southfield, MI

PostPosted: Sat Apr 04, 2020 2:04 pm    Post subject: Reply with quote

I dropped all the exhaust to remove mine this winter. I removed the wastegate with the pipe that comes off the back end of it still attached, I was too lazy to separate them.

I'm pretty sure I'd used a thin and short socket to get those bolts/nuts on the bracket; maybe a wrench as well. Then separating the wastegate from the boost line and such above and nudging it free. If I get mine back in place this upcoming week, I'll report back.
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'80 931 M471 - Dolomite Gray -> Monaco Blue
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bureau13  



Joined: 07 Sep 2017
Posts: 239
Location: South Florida

PostPosted: Sat Apr 04, 2020 3:23 pm    Post subject: Reply with quote

Thanks for the info! When you say all the exhaust, do you mean everything from the exhaust manifold back?

K-Roll931 wrote:
I dropped all the exhaust to remove mine this winter. I removed the wastegate with the pipe that comes off the back end of it still attached, I was too lazy to separate them.

I'm pretty sure I'd used a thin and short socket to get those bolts/nuts on the bracket; maybe a wrench as well. Then separating the wastegate from the boost line and such above and nudging it free. If I get mine back in place this upcoming week, I'll report back.

_________________
-----------------------------------------
1982 931
1986.5 Silver 928S
2007 Hummer H3 (Daily Driver)

Past lives (I miss them all):
2004 RX-8 (Wrecked)
1993 RX-7 (Sold)
1987 RX-7 Turbo II (Sold)
1985 RX-7 GSL (Stolen)
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K-Roll931  



Joined: 08 Jul 2017
Posts: 64
Location: Southfield, MI

PostPosted: Sat Apr 04, 2020 3:32 pm    Post subject: Reply with quote

bureau13 wrote:
Thanks for the info! When you say all the exhaust, do you mean everything from the exhaust manifold back?

K-Roll931 wrote:
I dropped all the exhaust to remove mine this winter. I removed the wastegate with the pipe that comes off the back end of it still attached, I was too lazy to separate them.

I'm pretty sure I'd used a thin and short socket to get those bolts/nuts on the bracket; maybe a wrench as well. Then separating the wastegate from the boost line and such above and nudging it free. If I get mine back in place this upcoming week, I'll report back.


Indeed I do! The only "exhaust components" left on the car as of now are the turbo and manifold. I'm pretty sure it's the only way.
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 1970
Location: Somerset, UK

PostPosted: Sat Apr 04, 2020 8:27 pm    Post subject: Reply with quote

Itís like a Crazy puzzle. The more you try not to take things off a turbo, the more you are forced to in order to get to the desired outcome. Bite the bullet. Remove it all and then renew all the fixings. Every last stud, nut and ditch the incorrect bolts.
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1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
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chuck21401  



Joined: 20 Feb 2005
Posts: 240
Location: Annapolis, MD

PostPosted: Sat Apr 04, 2020 9:10 pm    Post subject: Reply with quote

K-Roll931 wrote:
The only "exhaust components" left on the car as of now are the turbo and manifold. I'm pretty sure it's the only way.


+1
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chuck21401  



Joined: 20 Feb 2005
Posts: 240
Location: Annapolis, MD

PostPosted: Sat Apr 04, 2020 9:10 pm    Post subject: Reply with quote

Carrera RSR wrote:
Bite the bullet. Remove it all and then renew all the fixings. Every last stud, nut and ditch the incorrect bolts.


+1
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chuck21401  



Joined: 20 Feb 2005
Posts: 240
Location: Annapolis, MD

PostPosted: Sat Apr 04, 2020 9:35 pm    Post subject: Reply with quote

I was getting too much boost in my car (15psi) and needed to pull the wastegate. The exhaust from the turbo back has to be removed as mentioned above. The Haynes manual is somewhat helpful but doesn't tell the whole story. The factory workshop manuals and other technical bulletins are helpful. You may need to expand your tool collection. I've found swivel sockets to be very useful for working on my 931.

The first time I dropped the exhaust to remove the wastegate I didn't renew the hardware and everything eventually worked it's way loose. So I had to drop it a second time and replaced everything including the studs on the exhaust side of the turbo. That was back in November and everything is still tight.



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1981 Porsche 931


Last edited by chuck21401 on Sun Apr 05, 2020 1:41 am; edited 1 time in total
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chuck21401  



Joined: 20 Feb 2005
Posts: 240
Location: Annapolis, MD

PostPosted: Sat Apr 04, 2020 9:56 pm    Post subject: Reply with quote

Once you've dropped the exhaust and removed the heat shield(s), it is much easier to access the WG mounting bracket. I used CRC freeze off to help break things loose.






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bureau13  



Joined: 07 Sep 2017
Posts: 239
Location: South Florida

PostPosted: Sun Apr 05, 2020 12:47 am    Post subject: Reply with quote

OK, message received! Ugh. Well it's not like I'm not home a lot these days...

Thanks for the info...
_________________
-----------------------------------------
1982 931
1986.5 Silver 928S
2007 Hummer H3 (Daily Driver)

Past lives (I miss them all):
2004 RX-8 (Wrecked)
1993 RX-7 (Sold)
1987 RX-7 Turbo II (Sold)
1985 RX-7 GSL (Stolen)
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K-Roll931  



Joined: 08 Jul 2017
Posts: 64
Location: Southfield, MI

PostPosted: Mon Apr 06, 2020 7:17 am    Post subject: Reply with quote

I just got mine back in this afternoon. If you follow those directions exactly, it'll be a breeze! I could've saved an extra 30 minutes or so in mine, had I removed the wastegate pipe off the back. And with the heat shield removed, you have all the space you need for a wrench/ratchet combo to disconnect/reconnect the brackets.


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bureau13  



Joined: 07 Sep 2017
Posts: 239
Location: South Florida

PostPosted: Mon Apr 06, 2020 2:23 pm    Post subject: Reply with quote

I am now stuck on the heat shield, although I'm not sure if I'm mad at the factory or a previous owner. Basically, it's attached via a combination of phillips head screws and hex head screws. The three on the bottom were easy of course, but the fourth one is on a vertical surface, and it is fastened (at least on mine) with a phillips head screw because of course it is. The only way I can see to get to it is with a ratchet with a phillips bit but none of mine fit into that space. I've ordered a bit that I hope will work but WTF...you're already using a couple hex heads...PUT ONE THERE.

OK, done ranting...
_________________
-----------------------------------------
1982 931
1986.5 Silver 928S
2007 Hummer H3 (Daily Driver)

Past lives (I miss them all):
2004 RX-8 (Wrecked)
1993 RX-7 (Sold)
1987 RX-7 Turbo II (Sold)
1985 RX-7 GSL (Stolen)
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 1970
Location: Somerset, UK

PostPosted: Mon Apr 06, 2020 6:19 pm    Post subject: Reply with quote

PO or garage bodge. Welcome to turbo ownership. Repairs are a journey and a test of your metal
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
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chuck21401  



Joined: 20 Feb 2005
Posts: 240
Location: Annapolis, MD

PostPosted: Tue Apr 07, 2020 5:02 am    Post subject: Reply with quote

bureau13 wrote:
The only way I can see to get to it is with a ratchet with a phillips bit but none of mine fit into that space. I've ordered a bit that I hope will work


I inherited one of these from my father's tool collection. I was in a similar pinch...didn't have the right bit but was able to improvise with a phillips head bit from a cordless drill.

Turns out the company that makes this gadget is still in business, see:
https://chapmanmfg.com/collections/individual-parts/products/famous-midget-ratchet-cm-13

Decided to order some phillips head bits missing from my set so I'll be ready next time.


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bureau13  



Joined: 07 Sep 2017
Posts: 239
Location: South Florida

PostPosted: Wed Apr 08, 2020 6:03 am    Post subject: Reply with quote

Yeah, that looks like it would do the trick!
_________________
-----------------------------------------
1982 931
1986.5 Silver 928S
2007 Hummer H3 (Daily Driver)

Past lives (I miss them all):
2004 RX-8 (Wrecked)
1993 RX-7 (Sold)
1987 RX-7 Turbo II (Sold)
1985 RX-7 GSL (Stolen)
Back to top
View user's profile Send private message
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