924Board.org

jpab924 · Posted: Thu Aug 12, 2004 2:11 pm Post subject: Wastegate removal

Ok, parts have been slow to arrive and I figured it was time to drop the exhaust and remove the wastegate.

First issue is with the sealing ring from bypass pipe to cat. Came out in 3-4 nifty little pieces. -nick mentioned the pet not having the correct part # for the sealing ring in a prev. post. Before I look it up in the pet, has anyone else had a prob. finding this sealing ring? I`m definately going to need one.

2nd issue, the heatshield over the wastegate is rotted, and needs a new one. Or need to fab something up. I don`t think it should be left off.( I don`t know what that fireproof insulation is made up of under the heatshield....hopefully its not asbestos.)

3rd issue, I have the old style wastegate installed...meaning it has a vent line on top. Someone tell me, how the hell do I get to the fitting on top attaching it to the vent line? I see it runs somewhere up towards the back of the head, then I loose track of it. I was thinking maybe the wg could be removed with the vent line still attached to it. I`m almost ready to just cut the line off. (I have someone sending me a wastgate, and I`m not sure if it is the new style or old style)

other issues....well I`m sure I`ll be able to find a few more.

btw, turbine blades spin freely and I don`t feel any play.

Lizard · Posted: Thu Aug 12, 2004 4:24 pm Post subject:

as far as that vent line it goes up and a bolt on the distributor housing that holds it down if you do decide to cut it that is fine, just afterwards if the other wastegate doesnt come with breather on top or the line then just bent the pipe over so it sits tucked up behind the wastegate, so when you cut it leave enough room to be able to bend it over the edge of the wastegate, the other option is to take off the distributor (spark, not fuel) and then the housing for it (good time to replace as this gasket normally leaks oil) and then you should be able to trace the other end of it.
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3 928s,

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

PET says the sealing ring used to join the pipe to the cat converter is 930.123.134.02. I don't have the converter, so I can't confirm this is a good or current number.

But, I do have an old-syle wastegate, and that vent tube on mine just "hangs down". Well, I'll be!... I guess the dealership who replaced the turbo the first time around (in Germany back in 81 or so) put it on upside down...

I always wondered why it had a rubber section on the line.

(click image for larger photo)
Haven't had any problems what-so-ever running with this configuration all these years, and as long as you remember to install the line before re-hanging the thing, this way will work for you too. By no means am I going to run out and drop the exhaust to put it on the other way!!

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'79 Eurospec 931

jpab924 · Posted: Fri Aug 13, 2004 1:28 pm Post subject:

What a m-fer to get out...but its out. Removed the distrib. and found the vents end under the distrib housing. I`ll be damned, the control line and vent line were both attached to the same bracket and bolted under the distrib. housing. Even if the bolt holding the bracket down is removed, the two lines are spot welded to that bracket and would have to be cut to separate the two.

I ended up cutting the line off under the car....I took the easy way out.

So nobody else has had to deal with getting a sealing ring from the wg pipe to the cat. conv? I find this to be odd.

Lizard · Posted: Fri Aug 13, 2004 4:27 pm Post subject:

actually the sealing ring from the wastegate to cat is normally shot people just normally bolox something up for it, cant remember what we did on kenodogs car, but iirc we didnt get a ring
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3 928s,

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

...just curious... how different is the diameter, than the turbo<-->manifold and J-Tube<-->manifold rings? Can the same ring that is used in those locations be substituted?
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'79 Eurospec 931

Smoothie · Posted: Sat Aug 14, 2004 3:00 am Post subject:

The ring he's looking for is different. It's a thick fiber ring (asbestos?). I had to replace mine years ago, but I didn't reply because I have no info that's of any use - no part # and I don't remember where I got it, but at the time, I was contemplating just cutting off the flare on that pipe and using something like an EasySeal stainless steel band clamp. Not sure if they're made small enough though - I know for sure they go down to 2" (possibly also 1.75"), but don't know the diameter needed. JCWhitney carries them down to the 2" size. Approx $10

http://www.jcwhitney.com/autoparts/ProductDisplay/s-10101/storeId-10101/p-920/c-10101/catalogId-10101
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"..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

-nick · Joined: 16 Nov 2002 Posts: 2699 Location: Cambridge, MA

I was unsuccessful finding a replacement ring. I tried all the local exhaust shops (none had one small enough) then I tried some motorcycle shops (none were big enough!). I ended up reusing mine. It just had a single crack in it and I haven't noticed a leak.

You could always just blank off the WG inlet on the cat and leave the wastegate exit pipe open to air. It will only be loud when the WG is open.

-nick

Smoothie · Posted: Sat Aug 14, 2004 8:47 am Post subject:

The # in my parts list that I'd have used to order the ring is "sealing ring - 930.123.134.02". The metal ring that's the wastegate side equivalent of the flare that's on the cat side pipe is "supporting washer - 930.123.132.02" - just in case you're missing it.
I was using Tweeks, Performance, Automotion, Zims, PAR, IFC, Parts Werks, NAPA and a local Porsche dealer at the time, but like I said, don't remember where I got it. Of those, Automotion's merged with Performance and Tweeks calls themselves Mid-America or something and something happened at PAR and they were completely useless in filling an order I tried to place with them about 1-2 years ago, so they're off of my list now. Long story short you're best bet would probably be a dealer.

The pipe OD's measure 39.5mm (1-9/16") and 43.7mm (1-23/32"), so you'd have to find a band clamp even smaller than 1-3/4" to use the idea I mentioned earlier.
_________________
"..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

Smoothie · Posted: Sat Aug 14, 2004 8:54 am Post subject:

Whoops...a big bird just told me the part's been superceeded to 930.123.134.04 ($13.45) - http://www.pelicanparts.com/cgi-bin/ksearch/PEL_search.cgi?command=DWsearch&description=93012313404
I must say I prefer the old part #'s price of $3.20.
_________________
"..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

jpab924 · Posted: Sat Aug 14, 2004 1:40 pm Post subject:

Hey smoothie, you and the big bird did good. Thanks a bunch. I`ll place an order and let you all know if its the correct fit. Supporting washer is still there and in good shape.

One issue resolved, and hopefully another one. now I have to figure out what to do for a heatshield...no listing for it in the pet.

Thanks y`all.

Lizard · Posted: Sat Aug 14, 2004 4:54 pm Post subject:

I recommend aluminum or stainless sheet bent to shape for the heat shield
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3 928s,

Smoothie · Posted: Sun Aug 15, 2004 9:26 am Post subject:

The heat shield is "cover plate - 931.113.203.01".
I don't have one and never did, but never had an active cat either.

The big bird says it's special order, non-returnable and $28.51
http://www.pelicanparts.com/cgi-bin/ksearch/PEL_search.cgi?command=DWsearch&description=93111320301
_________________
"..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

jpab924 · Posted: Sun Aug 15, 2004 10:49 am Post subject:

Ok, where did you come up with that part number? I don`t see them listed in the pet. I need to make sure it is the correct one before I order it.

The heatshield up by the wg is a 2 piece shield. The front one stretches up and goes toward the rf engine mount. The one I need is the second one that slides under the car. Not the one above the cat. conv.

If its available, I`d be like a pig in...well you know.

Smoothie · Posted: Sun Aug 15, 2004 11:10 am Post subject:

I got the number from a printout of the parts microfiche. Also just had a look at the Pet and found it there also. (That sealing ring for the wastegate pipe to cat is also on the same page of the pet I just looked at.) The shield goes under the first section of the cat and attaches with 4 screws - check your cat near the inlet end for a bracket or flange that'll take 2 screws and another place ~14 or so inches further back for 2 more.
Actually, I'd use Lizards' idea and make one myself if I needed it.
_________________
"..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