Exhaust Manifold/Exhaust Cross Pipe - Revised
87porsche06Subject: New Exhaust Manifold and Exhaust Cross Pipe
Model
944 Turbo
Group
2
Part Identifier 2146/2610
Number
8711
September 21, 1987
During the 1986 and 1987 model year several modifications were made to the exhaust system of the 944 Turbo prior to engine number 45H01768. The purpose of this bulletin is to aid you in identifying the latest style components and determining which parts to replace. In addition, removal and installation procedures and some important repair hints are also included.
This information is arranged in the following manner:
Part A - Modification information
Part B - Parts information
Part C - Repair information
Part A - Modification Information
Exhaust Manifold Cylinders 1 and 4. Has new expansion element and modified flanges.
Exhaust Manifold Cylinders 2 and 3. Has modified flanges to adapt to exhaust manifold 1 and 4.
Shield A recess is added for expansion element.
Exhaust Cross Pipe Has new removable pipe for wastegate and one piece flange for manifolds.
Note: As interim production, exhaust cross pipes with removable pipe for wastegate only and previous 2 piece manifold flange were installed as of VIN 95HN151297.
Part B - Parts Information
Only new style parts are supplied for replacement. They are delivered as kits, Part Number 000 043 076 01, which includes the following:
Exhaust Manifold 1 and 4 951 111 131 05
Exhaust Manifold 2 and 3 951 111 133 04
Shield 951 107 065 02
Exhaust Cross Pipe 951 111 096 09
These parts are also available separately under their respective part numbers.
The following gaskets and seal rings must be ordered in addition to the exhaust manifold kit.
Gasket - Exhaust 944 111 196 00 (4 required)
Seal Ring 944 111 205 04 (3 required)
Seal Ring 931 123 195 00 (1 required)
Gasket - Intake 944 110 163 00 (4 required)
Part C - Repair Information
When repairs are completed, the car should have all new type parts installed. In some cases, the kit will have to be used. In other cases, only the parts of older design should be replaced.
Removal:
When repairing cars which require use of all parts listed in Part B, remove the exhaust cross pipe first. Removal of the intake manifold is therefore, advised. This has two advantages:
- Easier access to the top cross pipe-toTurbo mounting bolts and nuts and
- once the cross pipe is removed, the 1 and 4 and 2 and 3 manifolds can be removed from the bottom without removal of the exhaust manifold-to-head studs.
For removal of the intake manifold, refer to the 944 Turbo Workshop Manual, section 21, pages 21.6 to 21.7 up to and including step 9. In addition, remove the front manifold support bolt M8 and the dipstick tube bracket bolt. Also disconnect throttle switch plug.
Loosen the M6 bolt from the speed and reference sensor plug bracket and remove the two M6 socket head screws from the rear manifold support brace and remove intake manifold.
Before disassembly of exhaust parts, spray all bolts and nuts with penetrating oil to avoid seizing.
From above, remove the top cross pipe-toTurbo mounting bolts and nuts.
The lower bolts and nuts should be removed from below after removal of the engine mount heat shield and steering shaft heat shields.
To avoid possible damage to the Lambda sensor or wiring, disconnect the Lambda sensor plug and route the wire downward. Unscrew and remove the sensor.
Remove all remaining bolts and nuts, unscrew the CO sample tube connector and remove the exhaust cross pipe from under the vehicle.
From below, remove the two M6 nuts retaining the exhaust manifold heat shield and permit the shield to drop downward.
Remove all nuts and washers from the exhaust manifold-to-head connections. First remove from below the 2 and 3 manifold and then the 1 and 4 manifold and gaskets. Remove the old version manifold heat shield.
Installation:
Loosely install the new version exhaust manifold heat shield. On final assembly, the shield must be pressed downward as far as possible. A distance of at least 6 mm must be achieved between the expansion element and shield to avoid contact and rattling.
When installing the new exhaust manifold gaskets onto the cylinder head, note the type of gasket. Two types can be found in use.
1. Gray composite on one side - steel on the other.
This gasket may be installed in either direction, but be sure to install all 4 gaskets in the same direction.
2. Blue coating on one side - steel on the other.
This gasket must be installed with the steel towards the manifold side.
From below, install new version 2 and 3 manifold first and then install the 1 and 4 manifold. Loosely install all nuts and washers.
Install new sealing rings into the new cross pipe (seam faces groove) and loosely install cross pipe.
With all nuts and bolts loosely installed, lightly and evenly tighten connections in the following order:
1 - Cross pipe to turbo (M10)
2 - Exhaust manifolds to cylinder head
(M8)
3 - Exhaust manifolds to cross pipe (M8)
4 - Wastegate pipe to wastegate (M8)
5 - Connection for removable wastegate
pipe (M6)
Important:
The M6 connection between the wastegate pipe and the cross pipe must be tightened uniformly to the specified torque in several steps.
When all flange connections are properly aligned and pulled evenly together, final tighten the exhaust assembly.
Tightening torque of nuts and bolts:
M10 40+5 N-m (29+3.6 ft. lbs.)
M8 20+2 N-m (14+1.4 ft. lbs.)
M6 10+1 N-m (7+.7 ft. lbs.)
Note: If the wastegate connection is not properly aligned, the wastegate must be adjusted. The wastegate mounting bolt holes are slotted for this purpose.
Complete the installation of the exhaust manifold heat shield, CO tube, engine mount heat shield and steering shaft heat shield, and Lambda sensor. Be certain to correctly route the sensor wire to prevent damage.
Reinstall intake manifold and related parts.
Test drive car after completion of repairs long enough to allow the exhaust assembly to reach operating temperature. Check the exhaust assembly for leaks and allow the exhaust system to cool down.
Retighten all accessible nuts and bolts on the exhaust assembly to the specified torque.
Important
Retighten the flanges of the wastegate pipe connection on the exhaust cross pipe (three hole flange) and the connection between the wastegate outlet pipe and the catalyst connecting pipe.
When reinstalling the lower engine splash guard, make sure the 3 hole flange for the removable wastegate pipe has sufficient clearance to avoid touching and rattling.