Hi all,
First time on the forum.
Sorry for the repeat of an old question however.....

Noticed exhaust rattle and took a look every thing from then on is history.
No nuts on any part of the exhaust or Turbo. Header nuts down to 11mm from corrosion. LHS wastage seized, actuator arm corroded and broke. I don’t think this next one has been mentioned on the forum, The cores on both are so badly corroded that whilst removing the turbos the exhaust housing on the RHS Turbo broke loose as the corrosion under the clamps was so bad.
And lastly all the Oil pipes required cutting.
By the way I am doing this in my back yard/garden.

I have a lot of past experience in the UK Rally scene with my own Car and have had many RS Cosworth some with 450 fwhp but I think my brain has been Phased by the name Porsche and worry about< what is after all, oil pipe repairs. However I hope whith this forum to seek help form the massive experiance of the members.
Here are the big questions in order of my worries.

I . Has any body repaired any or all of the Oil pipes. Please don’t tell me just to change the pipes as I just want to know if anybody has done a good repair if not I am going to have to wing it and post my results.
2. The turbos are knackered, shafts ok and untill I removed them I did't know I had a problem!!! Can any one give me an idea of an upgrade turbo and the results gained by fitting them.
My car is a 2002 uk car with a REVO PSU +75 bhp on stock. On the rollers produced (on Shell 98 octane fuel) rwhp so about 495 flywheel graph shows 450
About to fit 100 cell cats and a free flow hand made exhaust ( C&C Glasgow).
So what would be a nice turbo without going to stupid. Its a Tiptronic and I don’t want that much more power. OK bit od a lie I have chase hP since I was 17 years old and thats a long time ago now. Every one wants more power so 500rwhp would be great.

Porsche Glasgow want £2200 per turbo, £1200 lab assumming no problems ( big laugh as everything is a problem and book time goes out the window) so would expect twice that for lab charge. I recon total cost would be very near £6000. So I am doing it myself.
After all its just a Car and I never want to take the car to Porsche again unless all else fails. I am happy doing all the servicing items my self. I am not even worried about the service book stamp. Its worthless if you intend to keep the car. Over here an Escort Cosworth in 1992 was about £30,000 and you could have spent £1000 per year on servicing. Sell it now and you might get £10,000 if you are lucky. There isnt enoght space in the book for stamps 20 years.lol
I really dont want to change my 996tt what else could I move on too. Its , for me, the ultimate. It has so much more potential as well.

Any advice would be great.

Thanks in advance.
Frank
Loch Lomond Scotland

 

for tuning you can check all the board sponsors because they have some good offers for the k16/16g and k16 billet

 

Frank
I had the exact same thing happen to one of my turbos this winter when I was doing a big overhaul. I know you don’t want to here this but I swapped the oil lines, pressure and return. I checked with a local hydraulic company if they could make me a set of stainless steel hoses (like brake hoses) but it was moore expense then the original parts. The waste gate actuators are simple to replace with aftermarket parts. There are a couple of companies in the Uk that can supply the parts for around 130£.
regards
Rob

 

Hi Frank
Good to see someone who likes getting his hands oily
Mine is a 2000tt. I also like to do as much work as I can my self. Just finished doing the plugs, new heat shields and clutch accumulator, the nuts around the Turbo were totally corroded like yours, got all the DIY off this site. The oil feed to my turbos was very rusty so interested to know how you get on in case I have to do something similar in future, maybe meet up sometime for a chinwag. I live in Innellan just past Dunoon so not far from you

Cheers Max

 

Hi Max,
Nice to hear from you.
I will surely post my toils.
Would be great to meet up, no problems at all.
Frank.

 

Frank

Just noticed your post on PH will follow your trials and tribulations on there

Max

 

I have dropped the engine about 3 to 4 inches ( Max you can get) and there were the rear vent pipes "Bold as Brass". They are no longer fitted to the car!!! Its true hose Porsche Hose Clips are a GITT to get off. I didn't tie a bit of string to the L/H side vent pipe and I will pay the price when I try to fit the new vent pip. I don’t know which way it runs.... Bugger.

I removed the Airbox, this helped and made it easy to find the L/H side oil supply pipe connector. I took the engine mounting back plate off as well which made it easy to get to the O/S supply pipe connector. Take it as said both supply pipes are now off the car. Yes.....

The 2 Oil return lines are more of a problem and this one is not going to be repaired to original. The 2 returns go back to the engine and are as badly seized as they were on the Turbo Drain Sumps. I had a go at removing them and there is no way I am going to mess with them any more. Get it wrong, game over. Looks like a big repair. So I rang Pirtek, the chap came out and took a look. Between us we have come up with a repair. I am going to buy all the pipes ( 6 of them) and fit the vents and supply and I am going to cut the new returns and connect them to the old pipes which I cut a few days ago. He has produced a neat looking in-line coupler using compression fittings which will take well over 300psi. 10mm o/d & 8mm i/d I am happy it will be a good and safe repair.

Just priced the hoses,check vv, o rings,seals etc.... £567 including 2 heat shields. Uhn I'm in the wrong business.
Will post more as I do more.

Oh I , I chanded the plugs as well whilst the engine was lower, although with no Turbos it didn't matter.

Frank

 

Good to see you got stuck in and had a go yourself Frank , what sort of fittings are you needing i can get you stainless 10mm Swagelock fittings from work if you can eait untill the start of next week.

 

Hi Neil,
Thanks.
He said he will drop them off tomorrow. They are in-line Male to Male couplings 16mm thread for nuts, 10mm olives. Similar to a domestic water pipe compression coupling except it is for HP Hydraulics.

I will take some photos and post them once I have the car running.
Still have to get the rear discs off and skimmed and the centre Rad has a problem. he bottom row is looking like dead mans fingers. I don’t think its too much pressure ( heads leaking, no smell or sign in the expansion bottle). I bottomed out quite hard on a lane a while ago, that and the amount of dirt I found lodged in that area might be the cause. Its not leaking at the moment but it needs replacing.
Frank.

 

No problem it will probably be Swagelock or Parker compression fittings , pressure wise you will be fine with either i was using them on a 30 Bar air system today.

 

Hi all,
Just got the word back form Vince (CR Turbos) both turbo cores are trashed. Bearings etc were ok but corrosion so bad that one core has collapsed at the flange where it connects to the turbine housing, causing wear on the turbine wheel. He has taken pictures so far as he strips them down.
He can fix the seized waste gate and will asses the actuators tomorrow.
Frank.

 

Hi all,

The saga continues.
Has anybody removed the water pump housing.
The Oil returns from the Turbos go into the housing and guess what. They too are corroded to buggery.
I have had a meeting with our Porsche Centre about the problems I am having. They showed me under a 3 year old 997tt ouch.......... Not as bad as my 996 but well on the way.
My advise, anybody with an unmodded 996tt check your exhaust and Turbos.

Just an update on the turbos.
C&R Turbos dud not need tools to dismantle my Turbo. The core broke open in his hands.

Once again, any help with Water Pump Housing will be very much appreciated as I have to remove it.

Thanks very much for any help as I don’t have a Turbo workshop Manual. Talk about "Flying Blind" I feel like I have had 2 fingers poked in my eyes by a Porsche Car. lol

ps Turbo Workshop Manual (CD) HELP PLEASE
Frank