Turbo install problems

[deflator]

I'm in the process of installing a big t28 killer turbo on my 95 tsi. I've run into a few problems though.

First, I broke off one of the 12mm studs on the exhaust manifold, the rest of the stud is still in the block. What do I do about that? Could I get away with just leaving that one stud out?

Second, the oil return line kit I bought from extremepsi needs the oil pan to be tapped and welded. Thats beyond my competence and equipment, so can I get away with reusing my stock return line for the time being? the t28 killer is direct bolt-on so it should fit.

Third, how on earth do I get the stock oil feedline off where it connects to the block? I can't get any tool on it, so I was thinking just cut the line close to the bolt and put a socket over it?

Thanks guys, this is my first turbo swap and its gone pretty well considering.

 

[ROOKIE1]

As far as the stud goes . Get by , to me , means to not do properly . I would replace it . It is an exhaust leak spot .

 

[1bad92awd]

Yes, replace the broken stud. You can run the car without it, but that will be an exhaust leak, therefore not giving as quick of a spool and the good performance you want from it. You could use the old return line if you really wanted to but again, the old line may have old particles and crap inside it, so that could eventually lead to a problem as well. What do you mean by you cant get a tool on the feedline?

 

[deflator]

I've got new mani. studs, but this old one broke off when I was removing it, leaving the end in the block. Is there some method to remove it?

 

[ROOKIE1]

Is there any part of the stud exposed ? Vice grips . Which stud is it ?

 

[bluetlr2001]

i had a broke one when i replaced my manifold also. I bought a set of bolt exstractors also known as an easy-out from my local snap-on man or you could go to sears and get a set. then all you do is drill the bolt out some and put the easy-out in it and mine came right out. Just besure to drill in the very center of the broke stud. And use a very sharp bit.

 

[TSiAWD666]

You've got to replace that stud. You're going to have an exhaust leak there and your turbo will not perform properly. Major lag if you can get it to boost at all.

As for the oil return line I've not seen your turbo or your line so I can't say unless you provide more specifics. The stock line is hard so unless the new turbo lines up just like the stock one, you can't use it as a whole. You could engineer a hybrid unit, cutting off part of the stock piece and using hose to connect to the turbo's piece, but again the devil is in the details with these things so you'd have to provide more info on the new oil drain line.

If you can cut the end and get a socket on the feed line if it were cut, why can't you get a wrench on it with the line in place? Even if that's not an option, if you think you could cut the line to get a socket on then go for it.

 

[deflator]

Unfortunately, the stud broke off with part of it recessed into the block. Its the 12mm one closest to the passenger side, on the top row.
I'll go to sears tomorrow and see if I can get that easy-out kit. Thanks.

I'll keep trying to get to the feedline, I can probably get a wrench on it if I remove more stuff

 

[ROOKIE1]

Big keys . Level , straight , slow , and steady . Plenty of penetrating oil . If something is in the way , remove it . You need to be as straight as humanly possible .

 

[deflator]

Ok, I got the stud out, only to now realize my oil return line kit from extremepsi wont fit the turbo. Would anyone happen to know what kind of return line I can use with a Big T28 Killer? Its a turbochargers.com turbo if that helps any...

 

[brandonzero0]

Is the fitting on the line interchangable?

 

[1bad92awd]

Ok, I got the stud out, only to now realize my oil return line kit from extremepsi wont fit the turbo. Would anyone happen to know what kind of return line I can use with a Big T28 Killer? Its a turbochargers.com turbo if that helps any...

Check on the website and see if they offer a new oil return line kit. Most places do but you have to purchase it seperately. I learned that the hard way on my first turbo upgrade.

 

[kmoore]

Ok, I got the stud out, only to now realize my oil return line kit from extremepsi wont fit the turbo. Would anyone happen to know what kind of return line I can use with a Big T28 Killer? Its a turbochargers.com turbo if that helps any...

From the sounds of it you bought the Evo III 16g install kit.

 

[deflator]

Is the fitting on the line interchangable?

-10 AN, but I talked to extremepsi and they said I need a fitting for a 14b/16g.

But heres a dumb question, is it okay to leave a car with the front on jacks for a week or more?

 

[TSiAWD666]

It's fine.

 

[brandonzero0]

Ya, My car has been on jackstands up front for about 3 weeks now.