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Turbo (un)install HOWTO with pics


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I didn't check this thread until this morning, so you will have to wait yet another 12 hours to get your satisfaction. If you want to relieve your tension, then lock this and I will create another thread. :p
I forgot what I was supposed to remember.
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Here we go. Your removal may be slightly different because I have aftermarket up and downpipes installed.

 

Remove the 4 tabs from the engine cover and remove cover. Your tabs may look different because I've removed the cover so many times that I have lost track of which ones were stock.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00423.jpg

 

It should now look something like this. The big blue cable is my stereo power and the thin white hose is for my boost gauge.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00424.jpg

I forgot what I was supposed to remember.
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Remove the three bolts shown, two for the bypass valve and one for the intercooler mount.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00425.jpg

 

Remove the two bolts here that connect the intercooler to the turbo.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00426.jpg

 

Lastly, loosen the hose clamp shown here that goes to the throttle body.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00427.jpg

 

Pull that intercooler outta there. Things should look a bit like this now.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00428.jpg

I forgot what I was supposed to remember.
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IIRC, there are 5 small bolts that hold on the heatshield over the turbo. Remove those and remove the heatshield. Things will look a bit like this.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00432.jpg

I forgot what I was supposed to remember.
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This is the part where it gets a little interesting because all the stuff is so cramped together around the turbo.

 

Next step is to drain about a gallon of coolant from the radiator, unless you like coolant everywhere like me. ;) After you drain, remove the two clamps off the coolant hoses to/from the turbo, then unplug the hoses themselves. The arrow shows the return hose, but the clamp is not visible. If you want to scare people on the road, just let the coolant get everywhere and burn off when you first drive around.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00432_2.jpg

I forgot what I was supposed to remember.
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Along with the coolant lines, the turbo also has oil lines going into it and going out of it. You can clearly see the line up top. We need to remove the bolt, taking great care not to lose the two copper washers on top of and below the banjo. Also remove the small bolt holding the bracket in place. We can't reach the line going out of the turbo yet. We have to wait until we get the downpipe off for that step.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00432_3.jpg

I forgot what I was supposed to remember.
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On to the downpipe. There are four visible bolts you can remove here. It might be a good idea to PBBlaster them and let them sit if you cannot easily remove them. Remove the bolts and set the heatshield bracket aside.

 

http://img.photobucket.com/albums/v334/wcbjr/DSC00432_4.jpg

I forgot what I was supposed to remember.
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As soon as you take the TMIC off, stuff a rag into the turbo compressor outlet. You DONT want to drop anything down in there.

 

Yeah, thanks. Forgot about that. The turbo is coming out and I always check it before going back in, so I don't have to worry about that.

 

I'll go back and reference your notes and update my posts accordingly later on.

I forgot what I was supposed to remember.
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