I just did a turbo and manifold swap last week, make sure you buy a exhaust manifold gasket, its recommended you replace it. It is a good idea to remove the turbo as well, it makes it alot easier to put the new manifold in....trust me. So what you want to do is unbolt the 16mm coolant feed and return from the turbo (dont lose the copper crush washers, your going to need them again) then take off the 16mm oil feed and return as well as the oil dump. Now your ready to take the turbo off,first off, unbolt the charge pipe, second take the band that holds the turbo to the manifold off, gently tap the turbo until it breaks loose from the manifold. once thats done, start unbolting the manifold....once u get old mani out, time to install new mani and gasket. Next is reinstalling the turbo...etc

 

thanks a million. I was afraid i would have to mess with the turbo lines . Wish me luck

 

Here's some picks, i hope they help in some way
This was the install....

 

Well, at least you'll have a nice 3" O2 housing in the end. A couple things that I would suggest but you don't have to do, since I've taken my turbo and manifold out a bunch of times are:

1. Watch the top coolant line on top of the turbo, I usually just tyrap that thing up, so it doesn't leak all over the place, especially when you are under the car - lol.
2. Don't be afraid to cut that stupid bottom heat shield, or notch it where it goes around that manifold support. It makes it easier to reinstall, or even better, leave it off. I just use the upper heatshield.
3. Make sure to check your bolts for tightness after running for a day or so, because they like to come loose, at least they did for me.
4. It sure helps to have a socket wrench with multiple extensions for going under the car, if you need to.
5. If you find the charge pipe coming out of the bottom of the turbo hard to get on, spray some WD40 on there, also works great for getting vac hoses on ALL the way easily.
6. If you have a punching bag, that would be useful as well for venting.

Anyways, just small stuff, but goodluck to you:thumbsup:

 

ratcheting wrenches will make you life soooooo much easier!
the bar going through the lower heat shield comes off by breaking loose the upper bolt on the driver's side.
***MAKE SURE THAT YOU USE LOTS OF PB BLASTER ON IT AND LETTING IT SOAK BEFORE YOU TRY TO TAKE IT OFF***

 

ok.. turbo is off.......however i have spent 2 days trying to break the top bolt on the drivers side of the manifold bracket that goes down to the block. I have soaked it in pb plaster several times and over 24 hours. I have tried an impact air wrench, a 1/2 inch wrench with a 2 ft cheater bar. Nothing is getting this thing loose!!! any suggestions before i end up rounding off the bolt and burning the car to the ground?

 

cut the bar... I know of a few people that have been running upgraded turbos with out that bar.

 

i don't know if that is an option. I am going to be running the stock manifold and turbo still. I don't want my manifold bolts to break off in the head from stress of the weight of the mani and turbo...not to mention the vibrations. I am sure the bar is very necessary. got all the parts sitting here to do the install and one bolt in the way!!! I miss driving this thing

 

well we ended up breaking the head off the bolt. I used a 2 ft cheater bar with a 1/2 inch wrench with an extension. Also used a 5 ft crow bar and a little leverage to keep the socket from slipping off. When it broke we took it too a friend who drilled the bolt out and tapped it for me. Then bought a new bolt and done.....long day .

 

broke a head bolt?!? do u mean exhaust mani to head bolt? either way, I know thats not fun!

 

No not a head bolt. I broke the head off the bolt that held the top of the bracket on. The block to exhaust manifold bracket/support.

 

Jesus, sounds like my luck man. Glad you at least got it off/out and re-tapped.