Broken turbo stud removal

[tenaciousd199]

While trying to replace my manifold to turbo gasket, the stud snapped. It broke so it is flush with the turbos exhaust housing. The turbo is still on the car. Is it possible to pull it out with the turbo still on the car? Would it be possible to coat the gasket pretty heavily in copper spray and torque the other three down to spec, or is that just a horrible idea?

 

[tsi4g63dohc]

you need 4.....dont bother with 3....theres 4 for a reason ...just take the turbo off and get the bolt out...with the turbo on the car it would be a pain trying to drill the stud out and so on .......

 

[LiquidX]

Replace the stud/bolt. If you can't drill it out or don't want to risk it, price out local machine shops and have them drill it out for you.

 

[BoostBuddyGSX]

Yeah man! Don't be lazy!! If you need instructions on how to remove a turbo in 20 min, lemme kno

 

[Damills]

This is very common its not too hard though if you pull just the exhaust housing out and leave your intake side in. I usually then take it to my local machine shop and get it lasered out/helacoiled. Good luck

 

[BoostBuddyGSX]

Drain the coolant. (stop #### at the bottom of the radiator MAKE SURE YOU HAVE THE RAD CAP OPEN!)
Drain the oil. (17mm)
1. Unbolt the downpipe (17mm x2)
2. Unbolt the exhaust bracket if you still have the stock exhaust (14mm x1)
3. Unbolt the oil drain line from oil pan. (10mm x2)
4. Remove intake tube.
5. Remove heat shield. (12mm x3 on top, 12mm x4? on bottom)
6. Unbolt oil supply line from head. (17mm x1)
7. Remove coolant lines flowing to turbo. (hose clamp x2)
8. Unclip o2 sensor by thermostat housing. (pigtail connector)
9. Unbolt turbo bolts from exh mani. (14mm x4)
And you're good! Just slide it out through the bottom!

YouTube - 2g GSX How-To: Attempting turbo swap with WTF ending
Here's a video with a few extra steps but basically the same thing. Hope this helped

 

[kenamond]

As I recall, you can't get to one of the bolts holding the turbine housing to the center section, and if that's the case, you can't get the hotside off without taking the whole turbo off. The 16g and 14b (I think) have a band clamp holding the turbine housing on which makes it pretty easy to take just the hotside off, but not on a T25.

As for the video, I wouldn't overtorque the oil drain plug, and I'd use the closed-end of the wrench to keep from stripping the head of the plug. And I'd seen pictures of that sealing ring stuck in the turbine inlet a couple years back...didn't know he was recording the whole thing though. Heh.

If you went on to watch the porting video, I'd just unbolt the turbine housing from the CHRA and O2 housing and clamp the part in a vice to hold it still while porting. Then you can also gasket-match the O2 housing to the turbine housing while you're at it.

 

[BoostBuddyGSX]

The 16g and 14b (I think) have a band clamp holding the turbine housing on which makes it pretty easy to take just the hotside off, but not on a T25.

You are correct, my friend.

As for the video, I wouldn't overtorque the oil drain plug, and I'd use the closed-end of the wrench to keep from stripping the head of the plug.

Agreed.

If you went on to watch the porting video, I'd just unbolt the turbine housing from the CHRA and O2 housing and clamp the part in a vice to hold it still while porting. Then you can also gasket-match the O2 housing to the turbine housing while you're at it.

Also correct and I agree. Aren't we getting a little off topic? ..

 

[jed344]

mine had broken stud when i purchased my gsx so i got ARP bolt kit to replace the studs

 

[kenamond]

Last poster reminded me that while you have the turbine/mani separated, take the stud out and toss it. Replace all four with bolts. That makes it easier to drop the turbo in the future, because the stud doesn't get in the way.

One of my bolts was broken, too, but the shank was sticking up and was finger loose .

 

[95mitseclipsegs]

Last poster reminded me that while you have the turbine/mani separated, take the stud out and toss it. Replace all four with bolts. That makes it easier to drop the turbo in the future, because the stud doesn't get in the way.

One of my bolts was broken, too, but the shank was sticking up and was finger loose .

For clarification use only, what is the thread pitch on the O2 housing bolts and the heat shield bolts?

 

[bjmauck]

If your going to drill it your self make sure to put a shop rag in the turbo so the shavings don't get in the turbo.