AOS question, while your in there...
 

well, its out, along with the turbo, and the huge octopus of a vacuum setup, all the guards, plates, brackets, ect.... its finally out!!!

is it worth it to clean out the inside of the AOS? or will I actually hurt it by doing so?
also, is the bolt that bolts the downpipe to the block really necessary? what a pain in the @$$.

doing all the seals for the aos, new heater valve, new dme temp sensor, new seals for top and bottom of turbo, cleaned grounds, new water outlet gasket on back of head, new exhaust gaskets, reseal intake, venturi delete.......anything else need addressed? I have been sort of following what technoduck and kdjones have done so far (thanks for the write-ups guys!) so if i'm missing anything, let me know

Many people leave that bolt on for the downpipe with no ill effects. My personal opinion is that the entire weight of the exhaust is hanging from the hotside of the turbo as the next bracket is after the dump tube. Alot of weight i think. But again many people leave that bolt out.. infact the shop that swapped my turbo (for the previous owner) left the bolt out. Just peace of mind for me. But for what its worth, no aftermarket downpipes have the tab for the bolt!

I personally had no problems putting that bolt back in, i just reached up from the bottom and threaded it in. Tightened up with a 1/4'' drive ratchet, a wobble and a few extensions.

I also put that bolt back on, even though it's a PITA to do.

Regarding the AOS, I soaked mine in Grime Reaper for a bit to clean it up a bit, but didn't do anything more than that. It's hollow inside, so unless the whole thing is plugged up with something (Highly unlikely), I don't think that it is that big of a deal to clean the inside of it.

Good luck with the upgrades!!

Cheers, Keith

thanks guys, i was looking at some aftermarket downpipes and saw there were no bolt holes for them to be attached to the block....as techno said. but it does make sense to keep the bolt too. I guess i'll find out how much of a pit it will be on install.

ok good, it is hollow, great, to the parts cleaner I go!

i'd put that bolt back in. read this;
http://forums.pelicanparts.com/porsche-944-turbo-turbo-s/446753-removing-aos-heat-shield.html

thanks nize, i'm planning to atleast try to get it back in....hopefully I will be sucessful

another question: my crossover has a nut welded to the (standing from drivers side fender) bottom right hole so the bolt has to be put in from the inside, not the outside. that isn't from factory right?

That is factory.

o, okay. maybe i just wasn't expecting it then. but it does make it easier...that, and if you take out the oxygen sensor as well.

so you all packed up for the move techno? back to cold and snowy?

Yup, it sucks.. was just outside doing some work on the car and was freezing my ass off. This weekend should be nice atleast, will probably pull the car out then.

ya, heard around 50 or so for here(sat and sun).....maybe i'll get to wrapping mine back up. got a couple more little seals today from pelican, and I think i'm set to complete it now.

http://forums.pelicanparts.com/uploa...1267750488.jpg
http://forums.pelicanparts.com/uploa...1267750503.jpg
little by little, the project will be put back together in the next couple weeks...

Jeeze, that's a beautiful clean looking engine. Wish mine looked like that!

If you want my honest opinion, calling it a "beautifully" clean engine goes 1 step too far. But I can agree, in that I wish mine looked that good!

"He who hezitates, looses at the tree."

thanks guys, a little elbow grease goes a long way I guess, that and some carb cleaner or purple power...and LOTS AND LOTS of rags!!!

okay, got the turbo and stuff back in, EVEN got the little bolt for the downpipe in as well!!!! BUT--i messed up the threads on one of the downpipe studs..........@#$%! so i guess i'll drop the exhaust when done and fix it. they come out like normal studs right? i'll also have for put a dent in the rear part of the exhaust cuz it keeps rattling/tapping off my rear swaybar.

Closer!
 

YAY!!! it runs.........but an unexpected coolant leak from the t-stat o-ring that runs to the turbo drug me down a bit, but its fixed now.

I have only 1 issue. my vacuum at idle is about 12...and while at idle, my wideband is at 15.8-16.4. lots on the lean side. checked all my vacuum lines, hoses and tried crimping some lines off, but still low vacuum (and running lean @ idle)

i know this should be an easy fix but i'm overlooking it...any common mistakes? I did do the venturi delete and have all new vacuum lines, and have a new line from the AOS to the j-boot.

any suggestions?

mods: MBC, 951 maxx chips, k26-8, cone filter, 38mm tial, 3 in cat-less exhaust, 3 bar fpr

ALSO: just got done driving it and it boosts as it should, runs 11.6-12.3 under full boost and while cruising 14.6-15.1. just idle is lean

Congratulations on getting it all sorted out!!

Regarding the lean @ idle: Have you checked your fuel pressure? Maxx chips call out a 3bar FPR, but the one I got (NAPA) turns out to run only slightly over 2.5bar. Maybe yours is something similar...

Again, congrats to sewing her up:)

Keith

thanks kd, i do have a 3-bar fpr, and @ idle is about 42psi with vacuum, unglugged-46psi

i was wondering if the idle control valve is out of whack...if it would cause low vacuum like an intake leak.