special tool

I just wanted to write this because I have seen some pretty hokey stuff lately with ham-fisted mechanics and the crossover.

There is no fault with the factory crossover system.
There is no fault with the SFR header system, it is BETTER fitting than the factory system.

The problem is ALWAYS user error.

The proper method to install EITHER system is as follows:
1.Loosen the 6 turbine housing clocking bolts until YOU CAN JUST BARELY ROTATE IT BY HAND.
2.If you cannot rotate it, soak it with PB blaster for a week or 2 until you can.
3.If you skipped step 1, you are an idiot, please stop reading this.
4.Install headers with header bolts (or studs) LOOSELY.
5.Install turbocharger with top section of x-over and downpipe TIGHTENED securely.
6.Install remaining section of x-over and front section of exhaust.
7.NOW CHECK FOR ALIGNMENT.
8.If any pipes are out of alignment and you can see that they will not bolt together without massive leaks, you either A. need to clock you turbine housing, or 2. your car hit the wall at Pocono at 157 MPH.
9.Now here's the kicker, stay with me now....
CLOCK THE TURBO!. Grasp the top X-over section and rotate until everything comes exactly into alignment.
10.If you are unable to align, see number 3 please.
11.If you rectify number 10, and are still unable, see number 8.
12.Tighten HEADERS FIRST at cylinder head.
13.Tighten all pipe unions (whichever type you have)
14.Tighten 6 turbine clocking bolts (13mm ATF)
15.You may leave out 1 clocking bolt for access reasons and still be safely leak-free.
16.Certain combinations of exhausts may STILL require you to clip the inside of the A-arm carrier SLIGHTLY, you are excused for this, and will not recieve National Medal Of Retard from yours truely.

adrial

I skipped step 1, so I stopped reading at step 3-- yet my exhaust went back together just fine.

Might I suggest a test fit before you go reclocking the turbo.

reno808

JIM:
1. you have to MUCH time in your hands
2. If it were only true. Or you can be like me and have it soaked since last x-mas and still not be able at clock the dam thing.
3. my favorite step
4. you should be rebuilding your motor as well with everything else. I do NOT want to hear any excuses on wed.
5. on you step 8. prt 2. are you talking from exp? you may want to ask Rob if he can instruct you.
6. All in all i guess it was a good write up hehe. I might use it one of these days.
7. dude you crack me up all the time.
8. people if you reading please read carefully as for these are the best instructions you will ever read for installing the crossover on a 951.
9. Jim you forgot the torque specs ON ALL da bolts 2. no pics
10. you should be working on M
11. wheres testa for that "Offical" certificate that Jim has been waiting for all these years????

ehall

If you were offended by either #3 or # 11....See number 3 and obey.

special tool

I thought I might skip the obvious for once, but I see I have been caught.....
OBVIOUSLY, this is for someone with a mis-alignment problem, or the first fit of a new turbo.
If you haven't changed the clocking of your turbo, like super-Adrial, then you should be fine.

Tom M'Guinn

In No. 5 and 9, are you referring to those modified/segmented (three-piece) x-overs Linsdey started?

PorscheDoc

Lol, next, throw ALL cans of PB blaster in the garbage, because you have to do things like wait 2 weeks for that crap to do anything. Pick up the phone, and call Kano Laboratories and order a case of Kroil. You won't ever use anything else.

special tool

Actually yes, that is an acceptable mod to my above rant.
The Kroil is better.

PorscheDoc

LOL

evil 944t

[QUOTE=special tool;4792145]I just wanted to write this because I am a ham-fisted mechanic and never installed a taint.

The problem is ALWAYS user error. Does anyone have a blue print for this method?QUOTE]

Good job tool bag. Are you sure you don't need to shave a little off the frame?

Auto_Werks 3.6

Tool, its always nice when listers take the time to make write ups like this. Hopefully it will help someone along the way... Especially since people who can't figure out how to work on their car properly usually go straight to the search function. Right? And hey, someone has to be a douche, why not you?

BlacknRedGT

Im going to give this to my mechanic

special tool

Exactly.

billthe3

Hey, I got the point after the other thread.

And a recent encounter with a large pinecone (see my thread complaining about steering vagueness in the 944 section) has knocked it out of whatever seal/alignment there had been before, so I'll get in there and fix it.