Removing Carrera Heat Exchangers?

[WydRyd]

I'm planning to remove my entire exhaust system next week, to fit some Schnell/GSF turbo headers, and would like some tips on how to go abouts doing this successfully, especially the heat exchangers.

I've heard nightmare stories about people snapping the nuts and requiring them to be drilled out from the heads

What tools do you guys recommend I buy before attempting this project? Gas torch perhaps, to heat the nuts?

I plan to soak the nuts/studs with KROIL penetrating oil overnight first.

Advice appreciated

[Joeaksa]

If you can leave the car sitting for a few days, spray liberally the nuts and such with a good penetrating oil. Do it several days if possible. Kroil is excellent but try several days if possible, if not then overnight.

Then slowly try to loosen the nuts. Even try to tighten them a bit, then back off slowly and with even pressure. If one is tight then get the torch out.

Buy the Porsche allen wrench and use it, its worth the investment.

[KCPSG]

PB blaster is one of the best penetrating lubricants I have used. But it would be helpful to have oxy/acetylene torch handy to give a little extra heat if needed.

[Zeke]

It's almost a given you will need a torch unless these have been removed recently. I have used the torch as a preheat before applying the penetrant. If you do not have an oxy/gas torch, this may help a lot. Heat the nut to hot, not cherry red (you won/t get cherry red with a plumber's torch anyway). Then, cool it with the PB or your favorite and let the stud suck it in as it cools. Do this a few times and you can take the nuts off that day, not a week later.

[Eric-325I]

Originally posted by milt
It's almost a given you will need a torch unless these have been removed recently. I have used the torch as a preheat before applying the penetrant. If you do not have an oxy/gas torch, this may help a lot. Heat the nut to hot, not cherry red (you won/t get cherry red with a plumber's torch anyway). Then, cool it with the PB or your favorite and let the stud suck it in as it cools. Do this a few times and you can take the nuts off that day, not a week later.

Great example of why I love this board! Thanks for the great tip Milt...

Eric

[WydRyd]

Thanks for the great tips! I feel more confident tackling this job now

My heat exchangers would have been removed about 2 years ago, when I had a complete engine rebuild done. Since it's a turbo'd Carrera, I'd think these heat exchangers/nuts would have gone through a lot of stress and I hope none are already snapped

[Scott R]

I don't know if luck played into tihs or what, but I pulled my engine last weekend to tear it down and I had to remove the exhaust system completely. I purchased the Pelican tool for the barrel nuts, and I used my snap-on swivel sickets for the rest. No oil, no heating on a dead cold engine and all of them came right off with no issues at all, the tool that Pelican sells was worth every penny for doing this.

[WydRyd]

Which tool is that, Scott?

[Zeke]

Originally posted by Scott R
I don't know if luck played into tihs or what, but I pulled my engine last weekend to tear it down and I had to remove the exhaust system completely. I purchased the Pelican tool for the barrel nuts, and I used my snap-on swivel sickets for the rest. No oil, no heating on a dead cold engine and all of them came right off with no issues at all, the tool that Pelican sells was worth every penny for doing this.

I think a little luck was on your side that day, but you're right, there's "no substitute" for having the right tool for the job.

I too, would like a link to the tool you describe.

[Scott R]

Originally posted by milt
I think a little luck was on your side that day, but you're right, there's "no substitute" for having the right tool for the job.

I too, would like a link to the tool you describe.

Milt, I ordered the:
Allen Heat Exchanger Nut Removal Tool (8mm) PEL-TOL-P243 $24.20



http://www.pelicanparts.com/catalog/shopcart/911M/POR_911M_ENGwiz_pg3.htm#item17




It fit perfectly, and is made from one solid piece of steel, it made the removal very easy.

[klaucke]

I always use an Oxy/Mapp torch for exhaust nuts and other real stubborn fasteners. You can get an extremely fine point flame and heat the nut completely cherry red w/o burning everything else around. I'm not that familiar w/ the Carrera HE's, so I'm not sure how accessable the nuts are, but I wouldn't even attemp to tackle this project w/o a good torch. You need oxygen for this type of stuff.

After I heat the nuts cherry red, they spin off like butter. Worth the time everytime. And don't get me wrong, I'm also a dedicated PB Blaster fan, but it is no match for a good torch.

[WydRyd]

Thanks guys. I think I'll invest in that special tool and an Oxy/Mapp torch. I know I'll be doing this a few times in the future, so I might as well have the right tools for the job

[Kroggers]

Would it work if you heated the engine by running the car, and then use the PB stuff. Would this work if you repeated it every day over a week or so?

[rs6er]

Originally posted by Scott R
I don't know if luck played into tihs or what, but I pulled my engine last weekend to tear it down and I had to remove the exhaust system completely. I purchased the Pelican tool for the barrel nuts, and I used my snap-on swivel sickets for the rest. No oil, no heating on a dead cold engine and all of them came right off with no issues at all, the tool that Pelican sells was worth every penny for doing this.

That's because they don't salt the roads in CO. I had to drill all of my studs out.

[Scott R]

Originally posted by rs6er
That's because they don't salt the roads in CO. I had to drill all of my studs out.

They do to some extent, however I don't think my car has ever seen snow before.

[Joeaksa]

Originally posted by Scott R
They do to some extent, however I don't think my car has ever seen snow before.

Thats really sad as a 911 with snow tires on it is almost unbeatable with a good driver. Drove my 911 all over Europe in all weather and if you have never tried it, you have missed a lot of the fun in the car.

Joe A

[KTL]

You can make your own specialty tool very easily.

Buy a 8mm hex key and cut the bend off of it. Insert the key in a 8mm 3/8 in. drive socket and you have yourself a specialty tool for the cost of one cheap hex key.