Installing a turbo for dummies

[gordyzx9r]

So, I need to put the turbo back on now that I have it back from PTE.  Taking it off was easy.  I have a feeling putting it back on won't be as easy. 

So, now what?

[earlbrown]

Get some Anti-Seeze for all the bolts.

And do the downpipe last.


I'd also flatten the exhaust flange and toss the copper gasket.

[larrym]

I find it easiest to bolt up the return line first

[Steve Wood]

and using studs on the return line instead of bolts makes it easier yet.

[Forzfed]

The above three posters pretty well covered it! 

[good2win22]

Looks like your missing one of the studs for the exhaust housing to mount to the header.  Unless it's still in the exhaust housing, you'll need one more

[earlbrown]

One other trick with the return line...

set the turbo in place and try to start the bolts.   You'll notice the return line needs to be moved one way or the other to line up...

remove the turbo and tweak the line a little.  What you're shooting for is for the return line to be lined up with the turbo while it's in it's happy place.   That way you only need two hands to start the bolts.


Also, make sure the flange is flat.  It's very easy to bend, and fortunately very easy to bend back. a couple pair of small vice grips with dull jaws make easy work out of it.  I like to leave a slight convex surface to it that way the bolts get to pull it down.

A thin smear of RTV on the flange, both sides of the gasket and the housing will fend off any leaks. Let the RTV 'skin over' almost to the point of being dry, then lock it down (just like on headers, only with a gasket)

[gordyzx9r]

Going to try to get this done tonight or tomorrow...fro m everything I hear, the return line is the hardest part.

Looks like your missing one of the studs for the exhaust housing to mount to the header.  Unless it's still in the exhaust housing, you'll need one more

The pic with the two studs and three nuts are the original.  PTE sent me three new studs (but no nuts). 

[gordyzx9r]

And the studs bring me to another question.

What size nuts are those?  I'm going to buy new ones for the install because these three old ones don't go onto the new studs very easily and if I remember right I have to use two nuts friction locked together to install them.

[larrym]

I think they are to be a distorted thread lock nut which makes them a challenge some times.


Elliptical offset nuts is a catch-all category that encompasses designs known as oval locknut or non-slotted hex locknuts,. The salient feature is that the threadform has been deformed at one end so that the threads are no longer perfectly circular. The deformed end is usually shaped into an ellipse or obround triangle. These are known as one-way nuts as the nut may be easily started on the male fastener from the bottom non-deformed portion, but are practically impossible to start from the deformed end. As the male fastener reaches the deformed section it stretches the threads of the nut elastically back into a circle. This action increases the friction between the nut and the fastener greatly and creates the locking action. Due to the elastic nature of the deformation the nuts can be reused indefinitely.

[Steve Wood]

they are....

I always ask Ed what size they are...

[gordyzx9r]

Return line, easy...matched right up.
The exhaust was easy...matched right up.
Putting the 4 bolts thru the DP and mother fucker...

[larrym]

That's another spot studs work well.

[good2win22]

Damn the luck!

[earlbrown]

Looks like there's enough bolt sticking up to bite down on it with a GOOD set of sharp Vice-Grips.