924Board.org

924guy · Posted: Thu Mar 03, 2005 8:19 am Post subject: Wastegate rebuild..

okay, so i got my new wastegate diapham/gasket/bladder and 1 bar 930 spring from Andial..ill have pics soon, but i popped in the new parts last night, though i have to take it apart again, forgot to replace a spring bushing/washer (ugh!) ..

i checked out a few diagrams i had, but not much help there, so i just pulled it apart.. six nuts under the main housing and up it popped. put the old spring side by side with the new, its about two "rounds" higher, and quite a bit stiffer..so much so that i can only assume that tmy old spring was worn out, as it compressed very easily compared to the new one , even taking into account the new one has a higher/stiffer rating.
the diaphram is sandwiched between an aluminum cup, and plate, the plate was stuck on there pretty good. took a few taps with my rubber mallet and a twist with my strap wrenches to pop it off. the old diaphram showed signs of crazing, but was still intact..i think it wouldve given up after not too long though.. i took a few pics as i was going, mostly to be sure id remember how it went back together exactly..ill post those later..

upon reassembly, i got the diaphram seated correctly, but i had a problem getting the spring to compress enough to thread a few nuts on.. i ended up litteraly sitting on it (with a piece of notched 2" thick wood over the top housing to protect it, and more importantly, me..) as i dont have a vice or compression clamp big enough to work.. now im about 170lbs, and i barely was able to get the housing seated (no pun intended) using most of of my weight ...
there are two copper type flat washers that the spring seats on, i forgot to put one in, so ill have to do this again..

did i miss anything??
_________________
Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha

goturbo · Joined: 15 Jun 2004 Posts: 88 Location: Massillon Ohio, USA

Seems like too much force to get it back together. I realize that you have the heavier spring, but I just rebuilt my wastegate with the stock spring and I was able to push it together with one hand and start the nuts with the other. I'm sure that you've got the correct spring if you ordered from Andial (thats where all my stuff came from) but you could check the spring rate and be sure. If you have a dial caliper and some free weights you could approximate the spring rate....

J1NX3D · Joined: 06 Feb 2003 Posts: 1333 Location: New Zealand

hi! what are the pt no's for all the bits needed for the rebuild??
cheers!
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'86 944

goturbo · Joined: 15 Jun 2004 Posts: 88 Location: Massillon Ohio, USA

Andial uses the Porsche part numbers and here they are:

900 910 097 02 8mm copper lock nut, 8 req. $1.35 ea
930 123 194 06 wastegate gasket , 2 req. $22.30 ea
930 123 210 01 wastegate boot (diaphram), 1 req. $59.95 ea
999 062 010 02 8mm studs, 8 req. $1.86 ea

I made my own valve guide, but I think they have it if yours is worn out. Lapping compound for the valve is extra. So are the carbide cutting burs, 8mm taps, nev-r-seez, and swear words that it will take to remove all the bits of rock hard busted off studs.

It could be worse, it could still be on the car.

J1NX3D · Joined: 06 Feb 2003 Posts: 1333 Location: New Zealand

cheers!

[edit] oh, how about the pt no for the 1 bar spring?
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'86 944

Zuffen · Posted: Wed Mar 09, 2005 2:22 am Post subject:

On a 1 bar spring it takes quite a bit of force to clamp it down.

I pushed mine by myself (6 ft 240lbs of pure meat no fat) and had another set of hands starting the bolts.

I don't see how a single guy could assemble it by hand unless he had a jig clamp.
_________________
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

924guy · Posted: Wed Mar 09, 2005 3:10 am Post subject:

it was quite a trick!!

1st- set assembly on floor, and "balance it" in the appropriate assembly order.

2nd- cut a notch in a piece of 2x4, to accomodate the top valve.

3rd- place said 2x4 atop the unit, and take a seat on it, increasing your weight slowly, while ensuring the unit is compressing in the proper alignment..

4th- after carefulling seating the top houseing (pun intended) thread on the washers/nuts as far as possible...

5th- torque to spec,not sure what that is, couldnt find specs..i just went a half turn or so beyond "snug" .. be sure to alternate nuts every turn or so , so it seats evenly (like a wheel.)

as for the p/n for the 1 bar, my andial invoice shows "AND 123 181 05" wastegate spring 1.05 bar.
_________________
Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha

924guy · Posted: Fri Mar 11, 2005 1:40 am Post subject:

new problem..

besides the two waste gate gaskets for the pipes, there is also a third gasket between the steel finned lower unit, and the aluminum upper "acorn " shaped part (sorry for the crude discription , spring housing maybe?) anyhow, i need that gasket, its round , like a washer, and i cant find a part number for it..

any ideas? its not shown in any of my diagrams...
_________________
Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha

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

I've never separated the two sectons of the wastegate, but can see the thing you are referring to. It looks to me to be asbestos-like material sandwiched in between two outer metallic layers. Maybe you could fabricate one from sheet stock? I've never seen a PN listing for the components of the wastegate or the turbo until members posted them here on the Board.
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'79 Eurospec 931

numbbers · Posted: Sat Mar 12, 2005 11:33 am Post subject:

I don't have the part number, but I bought mine at the dealer. I remember, it was a little overpriced, but not too bad.
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1980 924 Turbo

cleethorpes · Posted: Wed Mar 23, 2005 7:45 pm Post subject:

could you let me know the prices for the parts, just approx would be great!

The andial website doesn't seem to have any prices on it.
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'24 turbo with dodgy gt bodykit......needs a new home

cleethorpes · Posted: Thu Mar 24, 2005 2:50 am Post subject:

found wastegate springs in performance products catalogue.

$59.95 each for either the 1.0 bar or 1.2 bar springs.

they qoute for the 911 the 1.0 b is a 20% increase and the 1.2 a 33% increase.

Can the engine cope with 1.2 bar with a standard head gasket?
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'24 turbo with dodgy gt bodykit......needs a new home

Raceboy · Joined: 01 Mar 2004 Posts: 2327 Location: Estonia, Europe

Paul · Posted: Thu Mar 24, 2005 6:14 pm Post subject:

I hearing a boom in your near future....

cleethorpes · Posted: Thu Mar 24, 2005 8:04 pm Post subject:

Paul, you think the 1.2 may be pushing it a bit then?

Assuming the compression IS ok, the airs cold enough and I go the copper gasket route, should this (in theory) be ok?

I am fitting a 944 intercooler in the nose and will be wrapping the turbo, exhaust etc to keep the temp down.

Anyone else here fitted the stiffer one?
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'24 turbo with dodgy gt bodykit......needs a new home