Peanuts

iTrader: (15)

Im in the process of fitting my td05 to my 99uk (td04 as std.).
whats involved in the actual fitting of the turbo unit?
I have all the *supporting mods*, I just need to know what needs doing to the turbo before it will go on.
photos to back up script would be a double bonus!

Andy

AndrewC

All you need are the water pipes for the TD05 as the banjos are larger than those on the TD04 pipes. You may need to bend the bottom pipe a little to get it fit.

Apart from that it is a straight swap - assuming the TD05 is already converted to front entry.

Andrew...

FB Tuning

iTrader: (30)

I fitted one to the girlfriend's MY00 - It's not too bad a job so long as none of the bolts are seized.

From memory...

1 Disconnect vacuum pipes from actuator and compressor housing.
2 Remove TMIC
3 Remove exhaust downpipe
4 Remove water pipes, letting water drain down - You may want to drain all the water beforehandand do a coolant change.
5 Undo Intake pipe jubilee clip on compressor housing
6 Undo and remove oil feed pipe taking care not to drop banjos and copper washers
7 Undo the 3 nuts holding turbo to up-pipe also unbolting the bracket that ties the turbo + uppipe to the engine
8 Gently lift turbo up to remove.

When refitting the TD05 the bottom water pipe interferes with one of the gearbox to engine mounting bolt lugs. If you offer the turbo up you'll see where it makes contact - You can then remove asmuch of this lug as needs be with a Dremel / angle grinder or similar

The oil drain pipe can be a bit of a sod- It's held by a spring clip at either end. The pipe kept slipping down as I fittedd the turbo, so ended up removing and compressing the clips to make them grip the pipe a bit tighter.

It can be a bit fiddly getting the inlet pipe back over the turbo intake - a small screwdriver with NO sharp edges helped me.

Once the turbo was on I primed it with oil, pouring an eggcup full down the feedhole using a tiny funnel.

Putting it back together was fairly straightforward from then on.

I'd recommend that you get new copper washers for the water and oil pipe banjos You may also want to get downpipe and uppipe gaskets, although I didn't find these necessary.
If going by the book you should also do an engine oil change afterwards (although i didn't )

Also, If you're planning to fit an adjustable FPR, I would do it while the turbo is removed. I ended up removing the Turbo 1 week after fitting it so that I could fit a slightly longer piece of fuel hose to the fuel return rail and the 90 degree elbow that replaces the OE regulator ....Feckin sl@g of a job with the turbo in situ.

Run engine up...checking for oil + water leaks

It's almost easier to do it, than try to describe it !

If you need a hand - I'd be glad to help (for a pint or 2!)

Hope this helps

Richard

Peanuts

iTrader: (15)

where are you based Richard?

good instructions by the way.
theres a pipe on the td05 that has a banjo at the end, do I need to do anything to this pipe?
what oil did you put in the turbo, just engine oil?
where to get copper washers, halfords?

cheers
Andy