Big job just broke out!

As you all know, i've got a seized actuator on the N/S turbo. I put the car on the 2 post lift today and removed the bumper, N/S Intercooler, Exhaust, Intake filter box, light clusters and N/S wheel. I'm shocked at how rusty all the components are on the exhaust systems, I know there is alot of heat but why did they not use Stainless fixtures and fittings? The wastegate is very stiff going through the turbo exhaust housing and is difficult to free off, the actuators are rusty as hell and the two 6mm adjusting nuts on the rod have virtually disappeared. Bottom line is, I need a recon turbo :sad: Getting the turbo off was a bug*er, i've had to cut all three stainless pipes to the turbo and catch tank "aka" oil collection container, the pipe nuts have seized onto the pipes and when i try to undo, it started to twist the pipes. I can replace the 6mm pipe from the top of the block to top of turbo and from side of catch tank to near crank pulley, but the pipe from top of catch tank (10mm SS) goes somewhere over the top of the engine and turns into a flexi hose and I can't see the other end anywhere. I think I'll end up making a new end for this pipe and re-joining it. I have a few questions for you guys, 1) How much for a recon turbo (K16) and where do i get it from? 2) Will it come with a Oil Collection container and exhaust studs or will i have to get them from Porsche 3) If I eventually want more power should i upgrade both actuators now (car is factory standard at the mo) If so what type, only want around 480bhp. 4) The turbo has only been removed because of a sticky wastegate, is it possible for someone to repair the wastegate without changing the bearings and seals on the compressor. Only thinking of saving money for unnecessary work. Thanks for any help

It's disgraceful in the knowledge that Porsche design engineers have had a degree of practice in this field. Whoever was responsible for this cost cutting exercise at the outset deserves to be strung up now....... :gunfire: I'm sorry this isn't a very helpful post, I'm just equally disgusted in the choice of fittings on the exhaust system....

I have been in the trade for 25 years now and found the following two companies very helpful and competitive, they stand out as being market leaders in the UK and would no doubt beat any quote you get - http://www.universalturbos.com http://www.btnturbo.com My other advice would be for any bolt you remove in the exhaust / high temprature area replace with stainless steel bolts. Tip: Go for a low grade stainless bolt, ok it may suffer surface rust but it will never corrode. Many people make the mistake and go for high grade, expensive bolts, the more you pay the better it must be right? Incorrect. Stainless steel was not designed for exhaust use, it was meant for medical or food pipelines & fittings as it does not pass contamination, the higher the grade the better in this industry BUT the higher grade you go the more brittle it becomes. Therefore in the exhaust world it's purpose is to avoid corrosion, any amount of stainless (above 10% in the alloy) will achieve this and the lower the grade the more flex you get. Sorry for babbling on.

Thanks for that Lloyd, i've spoken to about 6 Turbo specialists today and they all say, they can't do a recon, only sell New. Cheapest price so far for a new genuine KKK is £950+VAT Porsche want £1832+VAT

Recon Turbos. If there is nothing wrong with the impeller part of the turbo's you are throwing money away. ask the guys just to recondition the exhaust housing and free the wastegates. if they wont do it find someone who will. speak to someone like forge Motorsport about new actuators, and get someone who knows how to set them up to fit them. Forge can recommend people who know their products. should save you a packet.

pm me the turbo details and i will get you a price for one.

Re: Recon Turbos. Thats just the problem, nobody wants to repair the turbo, only to sell new. As I said earlier, the compressor part is fine. I'm going to end up grinding the top off the wastegate shaft (covering all ports) and removing the wastegate from the housing, then ream the bore of the exhaust housing out. Not sure on the material of the wastegate shaft tho for welding it back on :?

Bad news but it just goes to show how the cost of a job can move in the wrong direction, especially around the exhausts and stripping it all down.

Turbo's Prety sure the shaft is MS and the exhuast housibg is nothing more than cast, dont think there is an insert and if there is turn one up if you have access to a lathe... Apart from the dynamic balancing equipment for the compressor wheels Turbo re conditioning is just normal engineering so you should be fine. I am away on hols till the 24th and would be happpy to help with this if you can wait that long, if not good luck

I've dropped the Turbo off at ITS turbo's in Batley, they are going to free of the wastegate and clean the housing's. I need the first piece of the 10mm Stainless pipe that comes out the top (vertically) of the Oil collection container on the turbo, I had to cut mine to get the turbo off. If I can't source one i'll have to get new pipe from porsche and cut the bottom off it anyway as i don't know where the other end of this pipe connects to remove it all?

Does this help: They are £42.42 +VAT each.

How did you find it for that price? Porsche want £65+VAT. Tell me more please :thumb:

That's the Porsche list price:

I get my parts from Wilmslow Porsche. Is that a trade price :? I've just spent over £300 on parts with them, I'm not in the trade tho.

It's the retail price. Phone another OPC and give them the part number. Ask them for a discount too. Quite a few will give PCGB or Tipec members 10%.