Turbo Removal

[SrS13]

We began work on my friends car.

I need to know the easiest way to remove the turbo. do we need to take the exhaust manifold and the turbo as an assembly? Because I do not see any other way?

thanks

[S13240]

Easiest way is to take off the turbo with the manifold and then start taking it apart from there.

[BuudWeizErr]

Those 4 bolts holding the turbo to the manifold are PITA to remove with the engine in the car. If the engine is already in, I suggest pulling the manifold. GET AN S15 EXHAUST MANIFOLD GASKET. It's multi layer metal, and does not leak. Also, this is optional, see about stronger exhaust manifold studs. Not super important though.

There are 8 bolts holding the manifold to the turbo, 2 hard lines towards the front of the enging on the exhaust side, one rubber hose at the back side of the exhaust manifold and one more hardline that plugs in behind the cylinder head. That last line is the hardest. You can either disconnect the hardline from the turbo itself; that is the easiest get out, but the hardest to get back in, and it kinda gets in the way when you are putting the assembly back in. Or you can disconnect the hardline from where it meets the rubber tubing in behind the cylinder head. This is easier to get off, but harder to get back on, and real hard if you break that line, because there is no room to work back there.

EDIT: After you have the new mani -> turbo gasket in, and those 4 bolts tightened down, bend the crap out of those little metal clips with needle nose pliers. That will stop the bolts from coming loose again later down the line. Trust me, you don't want to do this again in a couple months.

[SpeedRacer1]

Also use threadlocker (chemical you can get at an auto store) and I used locking washers though I know they dont do anything once they get hot. I broke my locking washer plate. Another alternative to the S15 exhaust manifold gasket is a copper gasket from mr gasket, the SR20DE one fits fine.

[SrS13]

do you guys by any chance know the torque specs for the exhaust manifold bolts??

thanks for the replies : )

also wondering: do we need to replace all gaskekst or just the exhaust manifold's??

[SpeedRacer1]

You could reuse a copper gasket, multilayer is a judgement call though. Those crappy gaskets that are organic are one time use, unless you are feeling bold and have lots of exhaust sealant. The manifold to turbo (square with 4 bolt holes) gasket can probably make it so thats a judgment call, as well as the turbo to 02 housing (5 bolt holed) gasket. The downpipe gasket should be replaced.

27-35 ftlbs is just about right on the torque specs.

[nlzmo400r]

taking a turbo out of an s13? and swapping in a larger one!, oo goodie, what size is going in?!

[BuudWeizErr]

I wouldn't use threadlocker. You'll never get the turbo off, unless you want to cut the bolts.

Just bend the crap out of those clips so that they actually conform to the bolts, and you will be golden.

[SpeedRacer1]

Use threadlocker... I remove my bolts easily everytime, yet they still give good resistance to show they work.

[turboex]

Heres how i would do it...I just had to swap my gasket on both my manifold and the turbo gasket as they both leaked. This took from about 7 at night untill 3 in the morning. A very big pain in the ***. I then purchased a hks2530 turbo and tublar manifold. This time i just pulled the motor out. Took a lot les time and is very easy to do. There just not much room in there to be moving around and them header bolts are tight untill the last thread. No fun at all