Aztec Performance Ltd

iTrader: (234)

Will be upgrading my turbo soon from a knackered TD04 to a IHI VF34 or similar.

1)Does this need to be done by a specialist garage or can a weekend mechanic manage it ok?

2) Also advise on how it is done?

3) Will I need to re-map it again (tek3 running 17.4psi at the mo)

Thanx in advance

Bob

greasemonkey

1: All depends how clued up the mechanic is! Replacing and refitting a turbo isn't particularly hard but it needs to be done right.

2: In the most general terms, probably something like this:
Drain at least half the coolant so level's below the turbo supply
Remove I/C and block throttle body with a plastic bung or tissue paper
Remove turbo heatshield
Remove downpipe, upper heatshield mount and lower heatshield.
Remove actuator/compressor pipes & fittings
Remove water supply and return hoses from turbo tails
Remove oil return hose from underside turbo tail
Remove oil supply banjo bolt (and seal washers) from block-side compression fitting
Undo turbo entry pipe jubilee clip
Undo bolts securing turbo to up-pipe/bracket and wiggle turbo up and out of the engine bay.

Refitting is basically the reverse of above. The only really fiddly bit is getting the oil return pipe off and then back on as it's a s*d to reach. You should be able to wiggle it onto the tail as you manoeuvre the new turbo into position, and then push it home from underneath once the turbo is in place. Job can be made easier by holding the spring clip open with a small tie-wrap or piece of wire, which is then pulled off with a long-nose pliers once the pipe and clip are back in place.

Before you fire her up, remove the crank position sensor and turn the engine over on the starter for 20 seconds or so to establish both oil and water supply to the turbo.

Probably goes without saying, but cleanliness is important. If the engine's covered in sh*t, give it a good clean before you start working, and make sure any open oil or water couplings/pipes are kept clean/sealed until the time comes to reconnect them.

Also a good idea to fill with fresh oil before running the car with the new turbo - doubly advisable if it's brand new.

3: Yes, remap unavoidable.

Aztec Performance Ltd

iTrader: (234)

Thanks for the detailed instructions. I will print 'em off and have a go (with some help).

Do I need a new gasket kit?

greasemonkey

May be able to get away re-using the old ones, but I'd buy a new set and have them ready. If you don't use them, take 'em back.

Aztec Performance Ltd

iTrader: (234)

Good thinking...Cheers mate

greasemonkey

Should have mentioned it in the main post, but just in case, make sure you also get a new pair of seal washers for the oil supply banjo. A new turbo will come with them, but if you get a used one.

If push comes to shove you can anneal the old ones to soften them back up, but new is best.

dowser

Rather than draining water, you can just clamp the hoses off. Less chance of air blockages in water system that way too.

Why not get the turbo ported and polished before fitting?

Talk to the mapper about the tek3 you're running now - assuming it was for a td04 it "should" be alright on a larger turbo. However, boost control will be all over the shop if using ecu control, and timing will not be optimal.

Edited to add: fill turbo oilways with oil before fitting it too!

Richard

[Edited by dowser - 10/19/2003 4:51:43 PM]