Re-Assembling and Installing the Turbocharger

Seth using a drill and a Dremel tool bit (the bit was the only thing small enough to fit, and my Dremel Tool was being serviced) to clean up a deposit on the exhaust casting, prior to re-installing the turbo cartridge.

Test-fitting the turbo to the intake manifold; this was also a chance to make certain that the intake casting on the turbo was clocked properly prior to re-assembly. It also made for a cool picture. :)

Seth tightening down the cartridge to the intake casting, making a complete, ready-to-install turbo. The initial disassembly was in order to clean parts, and while there was a brief scare that the cartridge needed to be replaced, it was determined that the play felt in the shaft was miniscule enough to be safe. This was, however, an excellent opportunity to clean up and paint the exhaust casting with a high-temperature paint.

The turbo installed on the engine. The oil drains through the same pedestal that holds the turbo in place, and the oil feed line can be seen snaking up the driver's side firewall, under the turbo, and up to the top center. Doesn't the turbo look perfectly natural there? Note that the timing gear cover and water pump are also installed.

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Main Page

Introduction to the project

Before the project begins

Removing external parts and accessories

Removing cylinder heads

Heads, gaskets, and the block after head removal

Removing timing gear cover and camshaft

Cleaning the piston tops

Cleaning the ins and outs of the engine

Final engine block cleaning with compresed air

Oil cooler disassembled

Parts ready for painting

Final painting preparation

Parts after painting

Installing BajaGringo drains

Installing the camshaft

Re-installing the camshaft

Assembling and testing the oil cooler

First steps of modifications for the turbocharger

Comparing the stock head bolts to ARP studs (lengthy!)

Installing the cylinder heads

Installing the head studs

Installing the valvetrain

Installing the intake manifold and injector pump

Assembling and installing the turbocharger

Last touches on engine assembly

Installing radiator

The Finished Project