924Board.org

924ttrouble · Joined: 27 Feb 2003 Posts: 59 Location: Lacey, Washington

Since I don't have a factory manual and I'm using the haynes book that doesn't tell me how to take off the exhaust manifold while the engine is still in the car any help will be apperciated greatly. Do i have to go from underneath the car to get to the other 4 bolts from the manifold?

Smoothie · Posted: Mon Mar 31, 2003 7:10 am Post subject:

I've never done this, but if I were about to, I'd spend about 1 sec thinking about how to remove the exhaust manifold before moving on and asking, "Can the exhaust manifold and head be removed as one?"
The most I've done in that area is remove-replace the turbo (without removing the exhaust manifold or head), so I know that can be detached. I've also removed the wastegate and exhaust, so they can be detached as well. I'm pretty sure you can remove the head with the manifold attached - then it would be easier to deal with those lower manifold bolts later while the whole assembly off the car.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

924ttrouble · Joined: 27 Feb 2003 Posts: 59 Location: Lacey, Washington

I throught about that to, but isn't the turbo attached to the manifold and I can only see two bolts on the turbo is there 3 bolts on it? I still have to go under the car to remove the exhaust pipe bolts right?

I'm asking because I'm trying to find a better way to do this with out going under the car if I can.

Smoothie · Posted: Mon Mar 31, 2003 7:51 am Post subject:

Yes - three bolts from turbo to manifold. It's a long time since I did it, but I did do it, so it's do-able (in-car detaching of the turbo from the manifold).
I never had to remove the head or exhaust manifold - so someone else will have to give details on reaching those manifold-to-head bolts.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Joes924Racer · Posted: Mon Mar 31, 2003 9:56 am Post subject:

So you dont want to get under the car
thats kind of understandable though
not the point of my response ...
Depending on the shape
of the bolts they might not be able to
be cracked loose..I take my head off
with my big aftermarket header
attached ...I think your gonna have to
get under there to reach some bolts
you cant get from above...If you pull
the head youll be able to clean up the
piston tops at the cost of a head gasket
which only costs around 36.00.
You should be able to get the whole
exhaust manifold and head off if I can
do it with a after market header and head.

_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

924ttrouble · Joined: 27 Feb 2003 Posts: 59 Location: Lacey, Washington

I jacked the car up and put it on jack stands, if there are three bolts on the turbo where is the third bolt located I still only see two bolts on the top? I felt around the manifold and didn't fell anything. If I take off the two turbo bolts and the two exhaust pipe bolts I should be able to pull the head and the manifold as one right?

924 turbo · Posted: Mon Mar 31, 2003 10:18 am Post subject:

The third bolt goes up into the exhaust manifold from below.

There's no way you're going to get the turbo off without getting under the car. There are three bolts (or studs) holding the turbo to the exhaust manifold. The one you can't see is the one you're going to have to get under the car to get. There are also four small bolts holding the turbo's bracket to the engine block. They are very difficult to get out and even more difficult to get in. Then there are four bolts holding the exhaust pipe to the turbine. Then remove the J-pipe between the exhaust manifold and the wastegate. Once you remove all those, and drop the turbo, you can remove the cylinder head to get to the exhaust manifold.

In my case, I removed the suspension crossmember, swaybar, starter, and wastegate to make the job easier.
_________________
Jon Furst

924ttrouble · Joined: 27 Feb 2003 Posts: 59 Location: Lacey, Washington

Wait a minute, Your saying that I have to remove the turbo to remove the cylinder head?

924 turbo · Posted: Mon Mar 31, 2003 10:41 am Post subject:

Good question. I don't know if you can leave the turbo on to remove the head and exhaust manifold. For some reason, I assumed you wanted to take the turbo off. Sorry about that. Either way, the third bolt (or stud) is right between the turbo and the engine block. It's quite difficult to get to.
_________________
Jon Furst

Paul · Posted: Mon Mar 31, 2003 10:46 am Post subject:

Pull the head with the exhaust manifold in place, just remove the J pipe to the wastegate and the 3 bolts on the turbo.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

924ttrouble · Joined: 27 Feb 2003 Posts: 59 Location: Lacey, Washington

Thank you very much That what I need to know

Since you have been repair 931 since 1977 what's a good web site to order parts from at a reasonable price?

Paul · Posted: Mon Mar 31, 2003 11:10 am Post subject:

I have a very good parts guy at one of our local Porsche garages that almost always matches any price I can get from anywhere else.

When I need just a few parts and I don't feel like driving 60 miles round trip to the Porsche garage, I've had great success with:

www.eurowebparts.com

924ttrouble · Joined: 27 Feb 2003 Posts: 59 Location: Lacey, Washington

new problem, I can't get the bolts off of the top of the turbo I shattered a u-joint on the allen head bolt and this after I been spraying the bolts with penatrating oil for about 5 days.I don't want to break the bolt in the turbo. Any suggestion will help me out. If you look down at the turbo at the passenger side of the car the two bolts on the turbo from the manifold are the right bolts?

Zuffen · Posted: Wed Apr 02, 2003 1:30 am Post subject:

Well if you do break the bolt it won't be that big a deal as you will be able to drill and extract it later. YOu might try heating the nut to see if it will break free.

Your going to want new hardware anyway if yours are that bad. Stainless studs don't cost all that much, just have to find a supplier.

You have to have a pretty good tool to get in there and use an impact to go back and forth to break it loose.

It is a bitch no way around it. Once you get it back together and if you ever have to take it apart, things will be alot easier. Your dealing with 20 years of rust there.

I haven't read the string of posts yet, If I can I'll give it a look and see if there is any advice I can give.
_________________
Bob Dodd - 924turbo@cox.net
931 1982, 944 1982 euro, 924S 1988SE, 93 968 tip 06 Silver Cayenne S, 06 Black Cayenne S

I have Way too many cars, parts for the 931,944 and 951

Paul · Posted: Wed Apr 02, 2003 9:42 am Post subject:

Here are the nuts you are after: