I will be pulling the turbo tomorrow and porting the wg. Any things I should expect to have a problem with? I have read almost every thread on this including the write up on teamfc3s. Any tips or tricks for getting certain parts out or getting them back in.

Should anything to done to the turbo (such as oiling anything) before it goes back in other than new gaskets for the engine/manifold, manifold/turbo and oil and water return lines?

I also will be removing the airpump and have a block off plate but have not received my dual alt pulley yet. What else should I remove besides the ACV while I'm down there. Do I need a block off plate for the ACV?

Thanks again. I plan on doing a full write up with pictures on pulling the turbo and porting the wg.

 

Prior to ignition, pull the fuse for the spark and fuel, crank the engine over a bit to lube up the turbo.

 

Yea, the bolts that hold the cover on the wastegate chamber can easily break off. I'd soak em for a few hours in liquid wrench. Mine were severely degraded and 2 of the 3 broke off and ended up breaking 3 extractors off in the bolts. I ended up just getting a S5 turbo and still have the S4 unit.

That's my 2cts.

Scott

 

You might want to remove the airbox and afm to give you more room to work around it. It shouldn't take more than 5 minutes to remove it. Are you removing it with the manifold or just turbo only?

Yeah, you need a blockoff plate for the ACV if you're going to remove it. I think you may need to cap some lines but I'm not 100% sure on that.

Ouch, ABS and full emissions. Let me know if you need any help Stan.

 

Thanks for the suggestions. I dont have a block off plate for the ACV so I may leave it for now. I am using a milwaukee power tool with aluminum oxide burrs. Hopefully that wont take me too long. After I port it can I just used compressed air to blow out all the shavings?

Dan H if I do need help I will send you a PM. This is the first time doing such a big project. Compared to suspension and exhaust mods this seems a little more nerve racking.

 

I'm starting to take her apart now. Please expect me to make emergency "I need help threads now!" all day today. Thank you that is all.

 

thats gonna be a serious bitch to do with the ABS pump in there. i'd take off the downpipe, then remove the turbo w/manifold and just drop it straight down. when i replaced my turbo on my S4 TII we just pulled the turbo straight up without the manifold and it was easy (keep in mind i didnt have the ABS pump)

take the turbo off with the manifold and try to remove it from under the car, just my 2 cents

 

Success!!

Got the turbo off in about 4.5 hours. It was not as hard as I thought. The hardest part was getting those stubborn hose clamps off the ******* coolant lines. Everything else was pretty easy. I spent about a good 30 minutes getting those coolant lines off.

Here are some pix I took while pulling it. I will be doing a full write up when I am totally done.


















This is enough for now. There are some more. I'll continue to post on progress of porting. I hope those aluminum oxide burrs are up to the job.

 

What do you think of the gaskets? Reuseable? I have a new one just in case but would like to reuse this one if possible. Supposedly has about 15k miles on this gasket.

 

all i see is red X's

anyways, i reused my turbo/downpipe gasket and the manifold/turbo gasket.

 

After porting for about an hour here are the pix. I am not done yet but what do you guys think so far?

before



after




My hands are shaking right now as I type this.

Can anybody else see the pix? I can see them fine.

 

bump