951 cross over pipe bolting procedure

[Belgian951]

Hi everyone,

First post here, but already have benefited a lot from all the technical articles on the 951 that Pelican Parts created! I'm hoping someone here can help me a bit with the procedure to replace an 944 turbo exhaust cross over pipe. It unfortunately is not an article that Pelican Parts has written themselves! If they had, I probably wouldn't have such a headache.

So, following the wisdom of the internet and a bit of my own logical deduction, I successfully removed the exhaust cross over pipe of my 1986 944 turbo. I - contrary to the wisdom of one particular website - didn't have to remove the waste gate at all.

However, when I want to put in my new cross over pipe, I can't seem to align the last 2 bolt holes of the cross over to exhaust manifold connection. The wastegate to cross over is 100% done, the turbo to cross over connections are all there (2 out of 4 bolts tightened), and I have 4 of the 6 cross over to exhaust header bolts done.

I'm thinking I need to loosen everything again ( ) but other than that I don't know what to do. I hope someone here has the magic tip for me!

[944 Ecology]

Don't tighten any of the bolts until you have all the bolts in place and a couple of turns on each bolt. Once you have that, start turning each of the bolts a turn or two at a time until they all start to tighten, then tighten them all.

Sometimes you have to take two steps back to make one step forward.

[nize]

Originally Posted by 944 Ecology

Don't tighten any of the bolts until you have all the bolts in place and a couple of turns on each bolt. Once you have that, start turning each of the bolts a turn or two at a time until they all start to tighten, then tighten them all.

Sometimes you have to take two steps back to make one step forward.

i think every 951 owner learned this the hard way. welcome to 951 ownership.

[Belgian951]

Thanks everyone.
So put everything loose, then tighten.
Is there a specific procedure or order to tighten things in? Or can I start randomly?

[944 Ecology]

Originally Posted by Belgian951

Thanks everyone.
So put everything loose, then tighten.
Is there a specific procedure or order to tighten things in? Or can I start randomly?

Start with all loose, then turn each bolt or nut two turns, then keep doing it until they are more than finger tight, then do it some more until they are stubby wrench tight, the do it some more until they are factory spec torqued. Make up your own tightening sequence and follow it.

[Belgian951]

Thanks.
I just wished pelican parts would make a tutorial on the whole procedure..

[944 Ecology]

Originally Posted by Belgian951

Thanks.
I just wished pelican parts would make a tutorial on the whole procedure..

Well, write it up and submit it to Pelican Parts... you do realize that this is a user supported forum, they just provide a place to post...

[nize]

Originally Posted by 944 Ecology

Well, write it up and submit it to Pelican Parts... you do realize that this is a user supported forum, they just provide a place to post...

yes! if you can write it up i'll include it in the 951 FAQ to help future folks. even better if you can provide some photos.

[Belgian951]

Originally Posted by 944 Ecology

Well, write it up and submit it to Pelican Parts... you do realize that this is a user supported forum, they just provide a place to post...

Actually assumed it was staff writing articles and the forums were just public.

I'll see what I can do but seeing as the car is already halfway done, I'll be missing some parts.

[nize]

staff writes the technical articles but seeing as the 951 is over 30 years out of production i doubt there will be any new ones. users have added a lot more info over the years which is featured in the reference list post here:
Porsche 951 (944 turbo) reference list

[Belgian951]

I would write an article but it seems my knowledge is not conclusive...

In another episode of crossover pipe shenanigans...

I got a completely new oem crossover as the one previously installed had a hidden crack. The new pipe is an original Porsche 1-piece xover and is in the car but the bolt holes at the exhaust manifold pipes don't line up at all.

With my previous xover pipe (which this thread was originally about!) these bolt holes also didn't line up but at least they did somewhat which allowed me to use a screwdriver as a lever... now I can't get a screwdriver in the holes.

With the new pipe:
I loosened all nuts on the exhaust headers(this was the trick I used last time to align everything, didn't work now)

All bolts from xover to turbo are in but loose (except for the tacked on nut bolt, this is almost completely in).

Xover pipe to wastegate is completely on the studs with nuts loose.

Again requesting the group's wisdom in getting this car back on the road...! Thank you all.

[nize]

can you post some photos that shows what's going on?

[Belgian951]

Originally Posted by nize

can you post some photos that shows what's going on?

I'll try to get some photos taken tomorrow, the car is not at my place.

[kdjones2000]

I would take off the bolts between the x-over and the wastegate and see if things line up well enough for you.

Then go back and match up the WG.

[Belgian951]

Got the pipe in! Trick was getting all bolts loose, remove the one bolt at the turbo tacked on nut. Then use C-clamps to get an alignment that will allow me to slide in a screwdriver, and then voila. Thank you everyone!