Hi all,

I'm just about to tackle installing a new set of headers and exhaust system and need a little advice.

I purchased the DesignTek race exhaust system from Design 911 in the UK and would like to do the job myself.

Do I need the special Porsche tool to remove the heat exchanger nuts or will a standard 1/2" universal socket extension do the job? Has anyone used a different socket extension or tool with success?

Can I reuse the old gaskets and nuts or is it recommended to install new ones? Do I use any gasket sealant and if so on both sides of the gasket? I know I should use copper paste on the threads...

Are there recommended torque settings for the header nuts or is a case of keep tightening until you get a good airtight seal?

Thanks in advance and I'm wide open to suggestions or advice on the best way to proceed!!

Neil

 

You will need a 13mm Allen head bit or Allen wrench to get the bolts/nut that is through the Heat Exchanger. For the one nut that I am having problems with I am going to use an Allen wrench 13mm or standard equivalents (NO ball end). I will stick the long end through the heat exchanger and then used a closed end wrench on the short “L” part of the allen wrench for torque.

As you may have seen, I am trying this right now. Its the same advice everyone on RL that has tried this is also recommending.


Here is some advice from a friend of mine that is doing some work on his 930 Engine and needs to take off his Heat Exchangers too.

"Don’t try crackin’ those heat exchanger bolts without AT LEAST some oil soaking overnight on them. I had a couple of mine come off very easily and others that POPPED off the stud with a ¼ turn of the wrench. I can fix mine easily because the engine is out. I did find a tool on line that acts as a fixture to locate the stud and hold the drill in place while you drill out the stud on the car.
I suggest to SOAK them with oil at least overnight. Slowly try turning them. If they don’t squeak or jerk as you start loosening them they might be about to break. Then I used a propane torch to heat them up. One still broke doing this but I have 29 years I’m fighting.

For the outer nuts on the heat exchanger I used special tool CRAFTSMAN ½ inch swivel socket (NOT SWIVEL EXTENTION). Yes ½ inch. I don’t know why maybe the nuts were replaced at one time or they shrunk from rust scaling."

 

Whoa, whoa, whoa ... You mean 8mm allen, right? The rest are 13mm nuts.

Use a "T" or get an extra long 8mm allen socket. The standard socket bit will not fit through the access holes. 13mm swivel socket and 13mm stubby wrench (spanner) would also be good to have.

The other tricky item is the cat removal. Do a search, if you're not familiar, but a 22mm wrench, penetrating oil, torch, etc. will help--especially with the O2 sensor.

New gaskets or gasket sealant are not required and you can reuse your hardware. But why not use M8 1.25 pitch 13mm nuts all around, instead of those odd allen nuts? Torque as you've described.

If any of the gaskets (rings) fall out, I'd recommend you reinstall with the help of some silicone sealant. Wipe everything off, apply a little silicone, insert, rotate and then hold in place. Since the gaskets will simply fall straight out without adhesion, it's a good way to keep them seated as your other hands are busy holding/installing the pipes.

Wipe everything clean after you're done and BEFORE you start the motor. Fingerprints, greasy residue, etc. will become permanent "beauty marks" on your shiny exhaust if you skip this step.

Good luck!

 

[QUOTE=joey bagadonuts;7038992]Whoa, whoa, whoa ... You mean 8mm allen, right? The rest are 13mm nuts. QUOTE]

Hmm...Maybe I will check tonight. I just seem to remember using a 13mm something,

I checked today...it was an 8mm Allen. Sorry about that.