Where did you get this definitive data on re- use of gaskets. I know my Porsche service manual , written by Porsche for Porsches, states that new gaskets must be used. BTW, they are not gaskets but Aluminum crush rings. There lies the problem, crush rings do not uncrush when removed. I changed my turbo several times and tried to reuse them and got nothing but exhaust leaks. There is a lot of labor getting to that point where turbine crush rings are needed, why cheap out and risk having to go back in there and do it over....

 

Using new gaskets is fine insurance and I certainly will not criticize the practice...it's just not always necessary.

KPG, that's unfortunate that you had exhaust leaks. Perhaps yours were damaged. Damaged ones obviously would require replacement.

Kevin, you make it sound as though the turbo, header flanges and exhaust flanges are rough and warped. All of these surfaces are machined flat. There are thousands of systems out there with turbo flanges that do not use any gaskets at all because typical flat sandwich gaskets on the turbine side will burn up and blow right out. The design of our inset gaskets is much better...and much more expensive to do. Porsche did it right. Anyway, I know several mechanics (Porsche certified) here and on both coasts that claim that because of the design they can be reused. If I ever develop a leak I'm sure I feel differently about it.

Finally, regarding the official Porsche service manual...do both of you follow it's directions 100%? No mechanics at the dealerships or in private shops do and I'm sure you don't either.

BTW, how do you guys feel about reusing the stainless exhaust manifold gasket?

 

I have heard from my tech friend (a p-car master tech) and from others on this board that "one" re-use of either gasket is acceptable. I am changing mine in the morning and will be replacing them both, they are $13.50 on Pelican, so I opted for the safe route, as you were saying, I don't want to go back and do it over. Section 21-30-19 clearly states replace with "new" on both, but as roadster say, you don't always need to do everything the manual says.
Great info from everyone.

 

i have kevins programing on my k24s with the evo intake and i haven't had any problems with it. you can port the headers while you them out it's pretty easy to do

 

You crack me up. It's not about saving a few bucks, it is what the parts are capable of handling. As I said above, I would never ever criticize anyone for using new gaskets. You really have been reaching...first the factory manual and now you describe warped flanges. If you have distortion in a flange, a new seal (especially one with a recessed design) is not going to fix the problem. If the flange is warped enough to need resurfacing then without question the seal is history. Throwing in expressions like "wing it" or "if you don't give a crap" are cheap emotional tricks that politicians use to make their point. You want to be right so bad.

 

This is getting fun. I didn't bother to reply to your "right" answer but I will since you brought it up. The carbon and road debris that you speak of will be limited to the area outside the surface that seals the mating surfaces. If the gasket is not damaged it can be reused. It is layered stainless steel, it won't "go bad." Having said that, there is no objection here to using a new one every time.

 

Where were you when I was building my motor? Heck, the head gaskets are multi layered stainless steel as well.... the money I could have saved

 

The notion of reusing a head gasket is idiotic. Don't be so careless with such statements.

Since you brought it up, how is that built motor?

 

Please, you said stainless steel doesnt go bad....does it go bad or doesnt it, you are the metalurgist The motor is doing great, thanks for the concern

 

The head gasket is exposed to exponentially harsher conditions and has a significantly more complicated role than an exhaust manifold gasket. I assume that you do indeed realize that and are just using this angle to place your insult.

I stand by what I said in my first post. Looking back at that post I forshadowed your and Kevin's reaction. I'll restate it: The exhaust manifold and turbo gaskets on the 996TT, by the nature of both their design and function, can be reused. That's all. Simple as that. It's done all the time whether you like it or not, regardless of what the factory manual says. Having said that, there is nothing wrong with replacing these gaskets with new ones every time. There is also nothing wrong with always replacing nuts and washers with new every time, but most people reuse fastners as long as they are in good shape...they are designed that way.

 

Actually there wasnt any insult in there, but apparently you feel the need to toss them around. The Porsche service manual isnt gospel, the clutch removal section will tell you that. I just want to know how you can speak with authority that you know better than Porsche on gaskets. Porsche wants caliper bolts replaced as well everytime the caliper is removed, do you recommend that or not. If you are a Porsche engineer, please say so. Please provide the hard data behind your statement.I will defer to your knowledge.

 

Well I edited the post to remove the solitary sophmoric insult immediately after I posted it as I felt it was inappropriate. You must have quoted me from the forum emailer. At any rate I do not have hard data. How could I? Why would I? All I have is information from more than one Porsche certified technician. These guys go to schools offered by Porsche on a regular basis and at these classes they get to know other technicians from around the counrty and even the world. One of them spent years at one of the largest Porsche dealerships in the world. This is a lot of experience with a lot of cars right along with many fellow techs doing the same jobs. The shared cumulative knowledge is on a level far different than one mechanic alone in his shop. I asked them about R/R the 996TT turbos and was told that these guys reuse the above mentioned gaskets. I can't prove it. It's fine by me if you don't believe it. I'm just sharing the info even though I know it to be contrary to what some believe. It should be this big of a deal but of course this is 6speed.

 

RD, if that insult was the worst thing that happens to me this week ...I am doing just fine. The thing about this whole thread is I actually agree with most of what you are saying. My tech is a 25 year veteran at a Porsche mainline dealer and he reuses the gaskets under most , but not all, circumstances. The point I was trying to make is there are people that may try to do this exhaust or turbo or both themselves and search the forum and see that you do not need to change gaskets. Maybe true, but the average DIYer doesnt have the knowledge of the mainline dealer or a good indy. It sure would suck to have to go back and replace them again if they didnt do it right. I think it is cheap insurance to replace all gaskets....per the manual

 

I by no means want to get in the middle of this debate, but roadsterdoc, since you apparently know so many Porsche certified mechanics and converse with them regularly...why is the Porsche workshop manual wrong? Who writes it (apparently Porsches' own mechanics are not consulted)? Why does this rag exist if Porsche certified mechanics ignore it? Just curious...TIA.

 

I think there has been some good information in this thread, in between the bickering about using a gasket more than once. Using new gaskets is always the best answer. I would only recycle a gasket "one-time" if I didn't have a new replacement, and the old one was in good shape. Always leak check your work, I do.
More to the point is, a turbo swap is for a intermediate to advanced wrencher. A seasoned guy is going to be able to differenciate a good gasket from a bad one.
When replacing turbos, I suggest having new nuts in-hand for the turbo flanges (7 nuts per side-header and cat), as these nuts are usually excessively heat soaked, and frequently the stud will back out of the turbo before you free the nut. Always soak all fasteners over night with a penetrant. I even go as far as replacing the header bolts. Remember to remove excess carbon from the header gasket interface for a better seal.
If you are just replacing the headers, I would have six new turbo studs and nuts in hand in addition to the gaskets, and be ready to have to thread chase the holes with a tap. Good luck and happy wrenching