1. You want to take out the entire exhaust manifold, turbo and turbine outlet at once.
2. To do thid you need to remove the exhaust manifold nuts, downpipe flange nuts, EGR tube nut, turbo support bracket bolt, the O2 sensor wire plug and the turbo oil feed pipe.
Soak all of these in a penetrating lubricant like "loctite freeze release" the day before and just before you start crankin' on them, a broken stud or bolt is the last thing you want.
3. Once you have this done you need to lever the EGR tube out of the manifold and pull the manifold, turbo and outlet away from the head.
4. Once you have enough room you can remove the coolant feed and return lines as well as the oil drain line from the turbo.
5. The whole lot should now be able to be lifted out.
6. Assembly is a reverse of the above, with the following points;
-Ensure that the replacement turbo is primed with oil beforehand, I use a syringe to feed oil into it untill it starts seeping out of the drain.
-Ensure that you replace the exhaust manifold nuts, if you reuse them they will come loose, ordinary locking washers will not work.
-New gasket are worth the money but as long as you replace the exhaust manifold gasket, downpipe gasket and any damaged turbo gaskets you should be fine.
If you want to dress the gaskets with silicone, you must use copper RTV or spray.
7. Fill your oil and coolant as per usual, remove the coil lead and crank the engine for ten seconds or so to prime the turbo oil feed line.
Then run the car with the radiator cap off untill the fan has turned on a few times.
The coolant will expand and force any air out of the engine.
I usually jam a filler funnel in the raditor neck to allow for the expansion while a watch for the level to drop, it usually takes another 3 liters or so at that point.
Last edited by mx_masta; 4-30-12 at 18:09..