Have the brand new turbo to replace the bad one on 83 coupe. Am about to start the 2nd assault friday on getting the intake off. Went to sears and got every possible 12mm tool to get to those tough lower intake bolts... swivel sockets - 1/4 drive wobble extensions, deep sockets, box wrenches - fully armed in 1/4 and 3/8 tools. Have read the archives on 3 boards - some conflicting info on if the heat shield needs to come off first.
Also have a gasket so I know approx. where the bolts are.
Any tips from anyone who has done it on a 82 - 83 turbo would be great!

In other news... going to a hydroulic shop today to see if they can make a replacement turbo oil line - teflon flexible braided ss with fittings. We will see.
It's a nightmare to get the stock line in and out of the engine compartment and I don't trust it anyway. Too many sharp bends for oil to coke up.
Will update and maybe get some pics.

 

You don't have to take off the manifolds to take off the turbo... that just creates a lot more work for you. Just gotta ubolt the downpipe from the turbo, and the exhaust back to the cat. Then unhook all the lines to the turbo, and loosen the 4 exhaust flange nuts.... and out comes the turbo. 3 of the 4 flange nuts are easy.... one is a biotch.

 

I looked at doing it both ways, if I had a lift - your method would probably be best. Also looks tough to westle it out the bottom with the steering in the way. Have already removed most prep stuff and fuel rail. Plus - when the old turbo went bad, it loaded up the intake system with oil and I would like the opertunity to clean everything out while I have the chance.
Also going the do some paint and polishing to see if I can make mine nicer looking than Bleach's before he has a chance to get his in.

 

I prefer to take the manifolds off as well. I can get them off in a matter of minutes and then the turbo is extremely easy to unbolt. I've tried unbolting the turbo with everything still on the car and it's just faster for me to remove the manifolds (the intake manifold anyways).

On another note, removing the lower intake manifold bolts only requires a 12mm socket (not a deep) and a long extension. No special type of sockets or extensions needed. If the heatshield you're referring to is the one sandwiched between the manifolds, then no it doesn't need to be removed. It would take quite a bit of time to get that sucker off anyways (if it's even possible). If you're hands are not to big then finding the lower bolts isn't too difficult. And for the love of pete, thread the bolts back in BEFORE you try to replace the manifold.

 

Thanks Jfairladyz
I have left the sandwiched heatshield on between the manifolds, took off the vertical one protecting the brake/clutch mastercyl area.
My hands are big but with the light and mirror I should be able to get to them.
I for sure will have the bolts started when I reassemble....
Should be a fun Friday.

 

yea when i took off my turbo and everythin i toook the turbo off first the one that is the toughest is the top left one and i think i got most of them off from underneath the car oh yea you may need to heat some stuff up to get the nuts broke loose (or mabey thats just me cuz i like in salty minnesota)

 

the turbo flange nuts were a bitch on mine. Car came from OH and it was in pretty bad shape as far as rust and corrosion went. A days worth of soaking in PB Blaster did the trick though

 

Update .....
Worked on it Friday and again today (Sat) in between the rain showers and got everything off ok. All the bolts came out fine - no breakage - used lots of pb blaster and deep creep just to be safe.
Pulled the intake off and then removed the turbo before taking off the exhaust manifold. Thanks to Bleach's help, I got the egr pipe disconnected, he has a couple of big adjustable wrenches that did the trick.

So I am all set... will clean up the intake and exhaust manifolds this week, pick up a new gasket and new custom oil line, reassemble, and be back in the blue car with a new turbocharger.
Thanks for the support...

 

hey dicesetter, good to hear its going well, read the canada section of the regionals and see if you can come to the meet up here with your car. the egr pipe nut at the top of the manifold is 1/1/4" wrench, but you may want to cut one shorter if you plan on doing that job more than twice.

 

Big F@#!ing wrench and a hammer. Thats my anectdote for the EGR piping Works like a charm.

 

All I can say is if it were me I with out even a second thought would be installing a pallnet STUD kit or paying a visit to Tacoma screw and getting some sort of... OK never mind Tacoma screw, but a STUD kit is the only way I will go through this pain in the *** job. Some of or most of the true journey men here know this is one hell of a bitch job especially for the average stranger... in a cold as hell greasy *** unorganized dead of winter garage here in Tacoma, as mine was at my time of doing this.

It made me very unkind as I went about it. That was a few months ago and I learned quite a bit from that job. First off a good deal of sleep prior to the job , dice I live in Tacoma and like to party I think you know what I mean. Any way anti seize the erg tube flare for future ease. good lighting a 1000 watt metal halide should be OK

. Yea man them make up mirrors Avon etc. A good harbor freight crescent wrench and some vise grips. All most for got a creeper I use a Continental skate board I had as a kid. Hey man I am just bus ride away I can help have tools will travel. Dice good luck man I am just fool in around a bit for real take your time all will be good.

 

I wouldn't say the stud kit makes it any easier. But I think it's a good idea for peice of mind that next time you go to remove the manifolds you're not going to break any hardware in the process. Breaking a bolt off isn't exactly fun But I dont see how it could get any easier then the stock setup. I can have both manifolds on or off in a matter of minutes (with all misc. items already disconnected) with the factory hardware and I'm by no means a fast mechanic. In fact, I tend to take my time. As long as you know where all the lower manifold bolts are then it's not that difficult at all. I've removed the manifolds enough times to have those lower bolt positions commited to memory

 

I may just go with the pallnet heavy duty stud kit, have not decided yet. I will use antisieze on all the fasteners in any case.
I ended up useing a 1/4" drive socket and extension with a 3/8 adapter and rachet to remove most of the lower bolts. Just knowing where they are is a big help and now that I have done it, I am sure it would go much faster the second time.
I took my time, want to do things right and have the luxury of driving the other zcar right now so I am not too pressed to get it running as fast as possible.

 

i got a header for my na, it adds to the fun, cause you cant use a extension and ratchet. although i just use a 12mm wrench it gets everywhere, also cutting the webbing out of the manifold really helps so i can see every nut. i take the heat sheild out just after doing the egr tube that doesnt exist any more and away i go, im sure the turbo cars may be a little more cramped, ive never really looked. lol

 

Must be nice to have it that easy and with the webbing removed. The turbo setup is more cramped - especially for the 2 above the turbo.
Will see if I can make it to the Canada meet - maybe Bleach will go as well.

 

Update.....
Finally finished all the work on the car last Saturday night. New turbo is in and runs great. Spools up verrrry fast and pulls hard. Am taking it fairly easy for the first 100 miles or so and will be changing the new oil again one time at 500 miles just to be safe.
Just a few minor issues to correct this Friday, fast idle on warmup which I tracked down to the TPS, the idle contact is bad so I unplugged it temporarily until I can replace it Friday.
Alot of work but well worth it.... lost alot of time between work and sick one weekend and moving.
Thanks to everyone for their advice and suggestions with the manifolds. And thanks to Bleach for the space to work on it.
Now on to the other upgrades....
Will get pictures up by next week.

 

good job!
I wish my turbo pulled hard.

 

Yours will very soon.... just a mater of some time and debugging the swap. Will give you a hand any time you want. And I've got to see that hood....
I'll be down all day Friday cleaning up the red turbo car to prep it for sale etc