How to Change your Turbo without removing the exhaust Housing.

[The Flying Moose]

Well as it has been mensioned a few times I thought I would post a quick guide on changing the Turbo withoutout changing the exhaust housing.

So when would this be advantageous? Well If you have say for instance a 15G currently fitted to your car with a straight flange exhaust housing and you have purchased a 16T or similar with an angled flange housing.

So this is what you will be starting with:



First you will need to remove the snake hose which connects the turbo inlet to your maf sensor housing. On this there are two jubilee clips which must be undone. The first is near the MAF sensor and the second near the turbo. These can both be undone using either a philips screwdriver or a 7mm socket.



Next its time to remove the intercooler pipework that runs accross from the top of the turbo to the lower intercooler connection. Once again like the MAF sensor housing this has 2x jubilee clips which must be undone. There is one near the throttle housing and one directly ontop of the turbo. Once these are undone you will also need to remove the 10mm bolt which secures the metal strap holding this pipework to the engine. Once this is done it should simple "pop" off. You may find you need to work it around the throttle cable. I have also removed the throttle body cover which is secured using a T20 torx, however this is not neccessary.



Next you will need to remove any strut braces you may have on your car. There are 3x 13mm nuts. on each side to remove.



Right we are now almost at the stage of removing the turbo, firstly however you will need to remove the Vacum pipes from the turbo body and the wastegate actuator. After this is complete you can start about the business of actually removing the turbo. On the turbo there are two water connections and one oil, of the two water pipes one is an inbound water pipe and the other outbound. This is becuase the TD04 series turbo's are water and oil cooled. All three of these pipes are secured by 17mm bolts which have two bango type gaskets/metal washers each. It is extremely important that when removing these pipes you do not loose these washers. These will be needed when re-fitting the turbo as without them oil and water will leak.

You may find it easier to access some of the pipes from underneath the car.

Once the top pipes are removed it will look something like this.



Its now time to go underneath the car. From underneath firstly you need to undo any of three water/oil pipes you could not remove from the top of the engine. If fitted you will now need to remove the figure of 8 shape bracket securing the oil return pipe. It has one 10mm bolt holding it together. Once this is done there are two allan type bolts which secure the turbo oil return feed pipe from the block to the turbo. These both need to be undone so as the pipe can move freely. It is not neccessary to remove the pipe from the block.



After this is complete the final stage is to return to the top of the car and remove the actuator rod split pin and lift the actuator rod from the exhaust housing seating pin. After this there is a 10mm bolt which holds the clip securing the turbo assembly to the exhaust housing. This needs to be undone. Once the securing clip is removed the turbo is ready to be taken off the car. It may be neccessary to gently tap the turbo with a rubber mallet or similar to free it from the exhaust housing. You must also be careful when removing the turbo from the housing to avoid damaging the turbine wheels.

When you are finished you should be left with a turbo looking something like this:



Fitting is the exact reversal of the removal process. Separating the donor turbo from its exhaust housing should be simple and easy too as all you need to do is remove the actuator rod and the clip securing the two assemblies together.

If you have any troubles or need any further advice please ask away

Cheers

The Flying Moose

[Niles]

turbo oil return 'bolts' are 5mm allens.

[graemewelch]

wish it was that easy when i had to remove turbo off my 2005 s60 t5. the turbo was huge and was almost impossible to get it out the engine bay. took over a hour of twisting it turning it upside down and skinning knuckles

[deathrider311271]

Fancy swapping mine for me mr moose???? lol beer tokens available

[Dangerous Dave]

One thing to add.

On mine it is nigh impossible to get a spanner or ratchet on the front water pipe on the CHRA, so I usually undo the clip on the rubber pipe which is at the timing belt end of the engine and extract the turbo with the one water pipe still attached.

[The Flying Moose]

Fancy swapping mine for me mr moose???? lol beer tokens available

No problem deathrider... you probably wouldnt want to watch me do it with some of my methods but I can change it for you no problem.