What to watch out for during turbo removal.

Try not to loose any of the copper crush washers for the banjo bolts. They are small, and easy to drop.

Don't bend the lines, and i use "Red GU" "Anaerobic sealant" Smeared in dabs on the copper washers and banjos to hold the mess together so the washers and banjos don't fall out of the lines during assembly. This works great. Its kinda Sticky but cuts the time and Effort of trying to keep the copper washers from falling off, Over and over again.

I put a tiny drop of superglue on the washers and glue them onto the lines when we take them off. Makes it easy to reinstall and not have to worry about aligning them.

Smaller-ish hands also help up in there.

So I think I'm looking at the oil feed and coolant feed lines. They are in a pretty tight spot so I see why small hands help lol. Well, I can't get a socket on them, so what did you guys use? I can fit a box end, but I'm afraid it may round off.

Should I remove the turbo manifold bolts, and the supporting bracket to try and move the turbo so that I can fit a socket? By doing that am I going to snap the metal feed lines?

NeedForSwede said:

So I think I'm looking at the oil feed and coolant feed lines. They are in a pretty tight spot so I see why small hands help lol. Well, I can't get a socket on them, so what did you guys use? I can fit a box end, but I'm afraid it may round off.

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While small hands do help, I have absolutely monsterous hands and I've been able to get em out just fine. Taking it out is the easy part... getting them back in is the tricky part. I hate snaking the turbo through all of the lines. Also, when tightening the banjo bolts, be very careful not to over tighten them as they will snap VERY easily due to being hollow. Just a warning.

Also, I find it's easiest to remove the oil line by the the oil filter housing. Makes life a lot easier. I was able to get the turbo out in about 35 minutes at night the last time I took it out, and had it back in in less than an hour in the pouring rain. Just tackle it, don't worry too much, it's pretty straight forward.

Ok so you left the hardline for the oil feed on the turbo and just disconnected from the filter housing? Also, did you use a box end wrench on the coolant feed? Thanks for the help.

I'm already taking it to a machine shop to get a broken stud off, but I would like to do as little breaking as possible lol

EDIT: Ok, ya the oil lines should be np now. Only the coolant feed is giving me trouble.

Well at least this is sorta on topic..

Does anyone know what size the copper washers are? I want to replace all of them and just need to know the size so I can go to Lowes or Home Depot...Any ideas?

Well I ended up going out tonight since I didn't really feel like working on the car haha. I just got back and I decided to give that line another go so I got the box end on the bolt and then took a rubber mallet (a hammer would have been better, but it wasn't handy at the time) and tapped it loose in seconds. Easy enough. Depending on when I'm out of work, I may even make it to the machine shop tomorrow after taking the td04 out.

Thanks for the help guys.

BluAero said:

Well at least this is sorta on topic..

Does anyone know what size the copper washers are? I want to replace all of them and just need to know the size so I can go to Lowes or Home Depot...Any ideas?

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I had to find some that were american and too small and dremel them out in the center so that they would work. You can only do this for a couple of them (I forget which ones, but I'm pretty sure it was the coolant lines), the others, you need to order from eeuro. I have absolutely no luck finding crush washers for the metric banjo bolts we have.

zingZACH said:

While small hands do help, I have absolutely monsterous hands and I've been able to get em out just fine. ...

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whoooaaaa!!!
you know what they say about men with BIG hands?

I've always taken the out through the top by taking off the manifold after trying to take one out through the bottom. Seems eaiser to me. I just undo the turbo stay,ic pipe, downpipe studs, coolant and oil lines on the turbo and out it comes. Then when replaceing it's easy too.

When I needed copper washers, I went to autozone and sized up some banjo fuel line washers that worked perfectly.

Saabeh said:

When I needed copper washers, I went to autozone and sized up some banjo fuel line washers that worked perfectly.

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Never had such luck... I tried every parts store in town (including AutoZone, VIP, Bond, Sanel's, A&M, and NAPA). All with no luck.