So the new breather was fitted and that part of the engine put back together. Next to remove was the turbo. Remove the air inlet pipe & oil feed pipe to the turbo before starting.
First the 3 bolts holding the exhaust side was removed
Then the 3 bolts to the exhaust manifold.
Then the two bolts holding the turbo mount to the engine, one is just below the exposed turbo to exhaust stud on the photo and the other is to the left of the picture just behind the EGR cooler.
Next is the bolt holding the oil return pipe to the turbo. Is the bolt in the middle of the image with green mark on it. Once that bolt is removed you can pull the pipe away from the turbo, however it will be stuck in there and takes a lot of effort to remove.
The final bolt which not not difficult to get to but easy missed is the lower bolt holding the turbo bracket to the engine. It is just visible in the centre of the image to the left of the little pool of oil on the turbo. Took me a while to find this last bolt as it's not obvious in elsawin.
Final pipe to remove is the intercooler pipe. I believe all the oil that is covering the hose clamp to the right is from the crank case breather, left is from the rocker cover gasket.
So a few days later the refurbished turbo came back
Fitting it is just the reverse of removal, just make sure the oil return goes back in, and make sure you fit a new o-ring, and all new turbo gaskets.
Next job while the engine is in bits was the rocket cover gaskets, also had oil coming from the injector covers.
Shots of the mess, you can see the oil on the bottom of the cylinder head cover.
And the oil weeping down the side of the engine.
The cover is easy enough to remove, however you will need to get new injector seals & o-rings, and injector covers.
You also need to get a set of these so you can torque up the injector pipe to the correct values, from memory you need a 14mm & 17mm.
All the bolts are easy to remove except the one shown in the photo just behind the fuel pressure sensor, yet another great design.
Also depending on how long the injectors have been in place you may find them difficult to remove, mine were fitted lastt that 2 years ago and the injectors came out with ease.
Once injectors are out, and screws removed you get the first chance to look at the internals of the engine.
Have to say I was please with the condition of the cams they showed very little ware. Also while the covers are off clean out the injector tubes, of any soot. Before refitting I brushed everything over with clean engine oil. and cleaned up the faces of the cylinder head and rocker cover.
Everything was then clean and put back together.
The right hand side was just as bad a suffered the same issues as the left.
Biggest problem in removing this cover was the bracket on the left which helps to hold the throttle body in place.
It's held in place by one bolt on the top.
Another shown to the right of the dipstick and two others below that bolt. However the lowest of the two bolt you only have to unscrew a few turns, you don't need to fully remove it.
Here is the bracket removed, you can see on the right the two screw holes that are hidden, with the very lowest hole being slotted.
Again I was please with the condition of the cam's.
Next was to start putting the engine back together. and clean up as mush as I could
then final stage of the cleanup was to remove the bumper and all the intercooler pipe work & intercoolers.
Coming up next is replacing the aircon pump....