Over the past week or so I have made steady progress with the Garrett turbo conversion..
I started by removing the air box, MAF, intake pipes, recirc pipes, heat shields, DV valve and any other associated parts..
Then I removed the turbo, water feed & drain, oil feed & drain..
The first attempt to remove the exhaust manifold didn't go to plan. I couldn't get enough purchase on the centre studs (they were actually Allen bolts as it would've been almost impossible to install it with studs and locking nuts) and eventually I had to grind the manifold away to get some heavy duty tools on it. The manifold had a large crack in it anyway so was destined for the bin..
I started to install the new manifold and one of the studs pulled clean out of the hole. The thread had been re-coiled previously and the coil had become loose..
Luckily Mark came to the rescue and posted me a re-coil kit the following day so I installed a new coil/thread.
For the second time I started to install the new manifold and one of the studs sheared off and got stuck in the head
I had to drill the stud out but luckily already had the re-coil kit so used it for the second time.
Third time lucky and the manifold went on correctly..
I then installed the turbo, routed in the new water and oil connections, TIP, MAF and temporarily the downpipe..
I still need to bolt the downpipe on, cut the current exhaust and link them together. The dump valve needs installing and I'm planning on making a couple of brackets to add a bit more support for the turbo as it is currently relying on the manifold flange only.
Fingers crossed she'll be running for GTI International on Sunday...