924Board.org

xplosive · Joined: 16 Nov 2003 Posts: 3 Location: Kansas City, KS

Ok, so I'm kinda new to the board (I've been reading it for a long time to solve some problems, besides its interesting) but I've got a question, i just replaced the head gasket on my '81 931 and I've got a nasty exhaust leak between the exhaust manifold and turbo, 1st I can't remember is there a gasket in there that may not be seated right? and 2nd is it easiest to loosen the head and fix that or does the turbo come off pretty easy? I've been a mechanic for the past 3 years and quit to go back to school so I dont have any problems pulling the head, its only like an hour off and a hour back on. Any advice would be appreciated. Thanks

Paul · Posted: Wed Nov 19, 2003 12:24 pm Post subject:

Yes there is a gasket there. It must be replaced everytime the turbo is loosened.

It will be a lot more costly to remove the head since you will need a new head gasket.

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

I beleive the 81 has a sealing ring (931 123 195 00) that sits in a recessed part of the turbo. The 80 has a triangular steel gasket (931 123 193 03). I have a 1980 car with an 81 turbo and I used both the sealing ring and the triangular gasket together. I think it would be easier to remove the head but you could try just removing the exhaust manifold and "J" pipe. The only tough nut to get at is the bottom of #4 cylinder.
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1980 924 turbo

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

There are several "variations" of the gasket setups, but regardless of the components, there will be a gasket of some sort between the turbo and the manifold. Simply going by model year may not be the right answer. If the turbo has a groove in it's flange where it mates to the manifold, I understand the sealing ring is supposed to be used. I've been told not to use both the sealing ring and the triangular gasket at the same time (don't know the logic, but that's the advice I was given. It sealed and ran fine with just the ring.) Does anyone have additional comments about using both the gasket and the ring at the same time? It would seem to me to not be a problem to run both, but with the triangular gasket in there, the ring would seal the space between the turbo and the triangular gasket instead of the manifold (essentially defeating the ring's purpose).
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'79 Eurospec 931

johnwalklett · Joined: 17 Nov 2003 Posts: 31 Location: staffs england

Not yet an expert so correct me someone if I'm wrong but.... You may find that you need to slacken the 4 pins that bolt to turbo to the crank case to allow you to install the sealing ring/gasket (I fitted both to mine when I fitted the turbo to my '82). This will also allow the turbo to be pulled up to the exhaust maniford as you bolt up the flanges. Good luck hope you get it sorted.

John

CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

Paul · Posted: Thu Nov 20, 2003 9:26 am Post subject:

Yep, its a PITA with the motor in the car.

If you don't mind the cost of a new head gasket set, I'd yank the head.

numbbers · Posted: Thu Nov 20, 2003 11:12 am Post subject:

'81 will have the crushable metal O-ring. You will need to pull the exhaust pipe from the turbo (there is a crushable metal O-ring in this joint that must be replaced also), then loosen both the turbo to exhaust manifold bolts, and the turbo to turbo mount bolts. You can then insert the O-ring. However, these O-rings are a Porsche part, and are fairly expensive, about $50 US for the pair. If you don't have a Haynes Manual, get one before you start on this.
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1980 924 Turbo

numbbers · Posted: Fri Nov 21, 2003 11:49 am Post subject:

I forgot, you will also need to loosen one of the clamps on the little hose that runs from the turbo to a vacuum/pressure pipe.
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1980 924 Turbo

Lizard · Posted: Fri Nov 21, 2003 12:14 pm Post subject:

ok if you guys think this job is hard, never buy a 928S3 or latter 928 model as they are way harder to work on,
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3 928s,