K04-015 Turbo Installation
(continued)
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- Remove the turbo mount bolt.
- Note that there is a plug and the bolt. Remove the bolt, not the plug.
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The bolt is a 6mm allen head. If your 6mm is
looking a bit ragged I strongly suggest you get a fresh one before starting. This
bolt was extremely tight and will strip easily with a worn
wrench. No, I didn't strip it. The bracket remains on the engine for the
duration of the install. Now is a good time to remove the oil coolant supply lines
(19mm & 17mm) with the exception of the banjo line. Ignore it for now. |
Loosen the turbo to cat bolts. The bottom bolt is easier to access from
underneath if you have a looooong extension and reach in from behind toward the front.
Do the 3 exhaust manifold to turbo bolts too.
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At this point wiggle the turbo forward to gain access to the banjo nut for
the coolant return.(watch the oil return line -- it likes to hang on part of the body down
below) Watch those banjo washers... then loosen the coolant line mounting bolt
(10mm) between the wastegate servo and the cold side turbo housing. Back under the
car, remove the oil return line from the turbo. (2 allen head bolts) |
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Survey for anything attached that shouldn't be... Wiggle the turbo out. |
Over on your bench, install the turbo to cat studs in the new turbo and transfer the
oil and coolant line fittings. I chose to prelube the turbo bearing. I just
dipped a straw in some oil, put my finger over the end of the straw to hold the oil, and
then filled the oil passage. Make sure you put oil in the oil hole and not the
coolant hole. Oil feed is the bottom hole. The thought of starting the car
with a dry bearing just makes me queasy.
Ok, now just throw yourself into reverse and put it all back together.
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Oh, don't forget to install the upgraded software... after you've washed
your hands of course. |
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Take a look at the cool looking belly pan. Air ducts and all. |
Points to note:
- Be sure to put in the turbo mount bolt before you snug up on the exhaust
manifold to turbo bolts.
- The banjo nut washers, technically, should not be reused. My kit didn't come with
them and it was too late for me to get replacements. Call me anal.
- Have fun with the oil return line on the turbo end... it was a pain to put back on for
some stupid reason. The line also likes to wedge on part of the body down below
while your scooting the turbo back into position. If things won't move $5 says the
line is wedged below.
- Take care not to overtighten the oil and coolant supply lines. They are
compression-type fittings and don't need much more than "snug".
- Fill 'er up with fresh oil.
- When you're all done start the car and let it idle until it's up to temperature... check
for oil, coolant, and exhaust leaks.
Intro
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