Engine Wastegate Removal and Installation Estimated reading: 4 minutes Contributors Overview This guide explains how to remove and install the wastegate on a Porsche 944 S2 with a 3.0L engine. While the S2 isn’t turbocharged like the 944 Turbo, this procedure assumes an aftermarket or custom wastegate setup tied to the exhaust system for performance tuning. The wastegate controls exhaust flow, and removing it can be tricky due to tight spacing and multiple bolted connections. This process is important for maintenance, upgrades, or troubleshooting exhaust issues. Tools Required Modified 13mm socket (grind down the open end to fit tight spaces) Ratchet Universal joint for socket 6-inch (152mm) socket extension 10mm socket 10mm wrench (two may be needed) Pry bar Flat tip screwdriver 8mm socket or wrench 17mm wrench 6mm hex key or long 6mm hex head socket Parts Required None Step-by-Step Procedure Step 1: Prepare the Vehicle Lift the Porsche 944 S2 onto ramps or jack stands to access the underside safely. Step 2: Remove the Starter Heat Shield Use an 8mm socket or wrench to remove the 8mm nut on the back of the starter heat shield. Loosen (but don’t remove) the two bolts on the side of the clutch housing holding the heat shield, using an 8mm socket or wrench. Slide the heat shield off the starter and set it aside. Step 3: Disconnect the Wastegate Diaphragm Hose Use a flat tip screwdriver to loosen the hose clamp on the wastegate diaphragm hose. Disconnect the hose from the diaphragm and move it out of the way. Step 4: Remove the Wastegate Discharge Pipe Modify a 13mm socket by grinding down the sides of the open end with a bench grinder until it fits between the discharge flange bolt heads and the flange recesses. Use the modified 13mm socket, universal joint, and 6-inch (152mm) extension with a ratchet to remove the four 13mm bolts securing the discharge pipe flange to the wastegate valve body. Use the modified 13mm socket and ratchet to remove the single 13mm bolt attaching the discharge pipe flange to the torque tube mounting bracket. Use a 10mm socket or wrench to remove the two 10mm bolts at the other end of the discharge pipe, where it connects to the main exhaust pipe. Use a pry bar to slide the discharge pipe toward the torque tube and downward toward the starter until the flange clears the wastegate valve body. Remove the discharge pipe from the vehicle. Step 5: Disconnect the Wastegate Inlet Pipe Use a 10mm socket or wrench to remove the three 10mm bolts on the triangle-shaped flange connecting the inlet pipe to the cross-over pipe. Step 6: Remove the Wastegate Locate the two 6mm Allen head bolts securing the wastegate diaphragm to the mounting bracket. Use a 6mm hex key or long 6mm hex head socket to remove these two bolts. Slide the wastegate (with the inlet pipe still attached) off the mounting bracket and out of the vehicle. Step 7: Install the Wastegate With the inlet pipe attached, slide the wastegate and inlet pipe assembly into position, aligning the inlet pipe with the cross-over pipe flange. Secure the wastegate to the mounting bracket using the two 6mm Allen head bolts. Tighten them to 20 Nm (14 ft-lbs) with a 6mm hex key or long 6mm hex head socket. Tighten the three 10mm bolts on the inlet pipe’s triangle flange to the cross-over pipe to 8 Nm (6 ft-lbs) using a 10mm socket or wrench (or two 10mm wrenches). Step 8: Install the Wastegate Discharge Pipe Position the discharge pipe, sliding it into the wastegate valve body flange and aligning it with the main exhaust pipe flange. Use the modified 13mm socket, universal joint, and ratchet to install and tighten the four 13mm bolts securing the discharge pipe flange to the wastegate valve body to 20 Nm (14 ft-lbs). Tighten the single 13mm bolt attaching the discharge pipe flange to the torque tube bracket to 20 Nm (14 ft-lbs) using the modified 13mm socket and ratchet. Tighten the two 10mm bolts connecting the discharge pipe to the main exhaust pipe to 8 Nm (6 ft-lbs) using a 10mm socket or wrench (or two 10mm wrenches). Step 9: Reconnect the Wastegate Diaphragm Hose Reconnect the wastegate diaphragm hose to the diaphragm. Tighten the hose clamp using a flat tip screwdriver. Post Procedure Checklist Check all bolts and connections for proper torque and security. Inspect the exhaust system for leaks by starting the engine and listening for unusual sounds. Ensure the wastegate diaphragm hose is securely attached with no air leaks. Sources Clark’s Garage Pelican Parts Porsche 944 Workshop Manual, Volume 1 YouTube Tagged:Wastegate Wastegate Removal and Installation - PreviousWastegate – Fabricating and Installing ShimsNext - Wastegate Removal and InstallationWater Pump Information and Replacement – 2.5L NA
