I'm waiting for a pair of Alpha 28's to be shipped to me and I plan on installing them myself. I have three questions for those who have done this upgrade.

1. What are the parts (part numbers if available) I need to perform the install? I'm referring to gaskets, seals, o-rings, studs/bolts/nuts...anything that should be purchased in advance so I'm not stuck in the middle of the install searching for missing items I need.

2. I have not ordered the intercoolers yet but I am going to upgrade to 997 GT2 RS IC's. Is it advisable to do them at the same time or can I get by with the stock IC's for a while?

3. On the one DIY I have seen, the exhaust manifolds are removed and then the turbos are separated from them. Is it necessary to remove the exhaust manifolds to remove the turbos or can I leave them bolted to the engine?

Also any pitfalls you experienced that could have been avoided would be super helpful!

Thank you in advance for any replies

 

1)

There are all the oem gaskets / rings for turbo and manifolds swaps. Assuming the alphas use the same crush ring style you would need:

2 of each:

Manifold to block gaskets: 996-111-107-71
Manifold to Turbo: 996-111-215-70
Turbo to Cat: 996-111-217-70

Bolts for manifolds (18 total): 900-378-227-09

2) Yes, but I'd strongly advise doing them. You can get away with them on low boost, but they'll heat soak quickly, especially with the output from the alphas. If you have the option of doing them at the same time, do it.

3) Remove the manifolds, you want to replace all those bolts anyway. You can leave them on, but taking them off makes the process much easier. They are not difficult to install.

I don't have the part number for the 6 replacement nuts you'll need from the manifold/turbo off the top of my head.

This should be a good start.

 

ECS Tuning has a full parts kit for turbo replacement. All necessary gaskets, nuts, etc: http://www.ecstuning.com/Porsche-200...ger/ES2608646/

They also sell the 997.2 intercoolers for a decent price compared to other sources...

 

I'm doing this now. Read this thread. Don't know about yours but on mine just about every bolt was badly corroded. My exhaust is pretty new so those are OK. I didn't loosen the manifold and used a nut grabber socket that are intended for stripped bolts. Took them off pretty quickly. You'll obviously have to replace those. You'll need new exhaust and manifold rings.

The real PITA was the oil lines. They will loosen from the turbo if you heat them well, but except for the top ones going into the check valve the nut turns and won't release from the line itself, causing the line to twist. I messed up the passenger side line into the back of the oil tank pretty badly and decided to replace it. On the others I gave up and was able to get the turbos off leaving the lines in place. Hopefully yours will be in better shape.

In the end you can't anticipate everything you might have to replace. In addition to the rings, exhaust bolts and manifold bolts, many people replace the check valves. I am. While there you should do your plugs and coil packs. If you want the pertinent pages from the PET catalog, PM me with your email address. It's too big to upload here.

 

I was following a different thread where you explained your issues and I felt bad for you! I just did my plugs and installed 997 coils a few months ago so I will leave them alone. The turbo kit I purchased is from TiAL (through EPL) and on their web site they have a pretty good DIY that explains how to connect the oil and water supply lines. I'm going to re-use the exhaust manifold bolts but replace the studs and nuts connecting the exhaust to the turbine housing. Does anyone know the specific hardware that is used to fasten the turbos to the manifold and to the exhaust? I know the turbo is mounted to the exhaust with studs and nuts but I do not know what sizes to order and I have never separated the turbos from the exhaust manifold so I have no idea what they are connected with.
I checked out that ECS kit but it has strange quantities that don't match the count of fasteners I need and wastegate hardware that I do not need.

 

When you do the turbos replace the studs and use Stainless nuts with Nord lock washers. The nord lock washers are brilliant for the turbos and all exhaust flanges that are bolted together.

http://www.nord-lock.com/

 

I found the answer to my own question, and I thought I would share it for anyone interested. Each turbine housing uses 7 M8 X 1.25 studs (4 for exhaust pipe and 3 for manifold side).