did the repair today to fix the broken studs so i thought i better put a bit up about what to look for when fitting dump pipe or removing turbo.
while you can get the stock dump/cat off without removing turbo, its not recommended simply because the odds are your going to break a stud off which means removing the turbo to fix it.
its fairly straight forward to get the turbo off the ZD30 motor so i won't go through all the "follow your nose" details.
don't forget to unbolt the oil drain before undoing manifold bolts.
i left a rear bolt in and a bit of wood under the turbo so the turbo won't fall down and crush the oil tube when you undo the bolts. (especially so if you have the heavy cat still bolted on)
working in a bit of lube can help amazingly well.
AFAIK these have titanium studs which have a nasty habit of grabbing then breaking. hence why you tend to break them off.
once you have got the turbo off, remove any broken studs and clean threads with tap to remove any broken bits still left in.
if at all possible fit new dump pipe on while turbo is out of the vehicle. it can be done while turbo is in there but getting to one of the rear bolts is very tight.
odds are you will break a stud off the turbo-dump pipe when removing the cat hence why its best to do it on the bench rather than in car. remove the broken stud and tap out the threads.
re installation tip...do not tighten the main turbo-manifold bolts up tight, keep them loose so you can line up the drain bolts. once oil drain is bolted in then bolt up turbo.
don't forget to bolt up new dump pipe support bracket. you may have to bend the bracket to suit. it needs to line up spot on. try not to have any tension on it when its all bolted up. this will help stop the dump pipe cracking.
obviously big thing here is your going to do an exhaust upgrade at home is having replacement studs, gear to remove broken studs and clean up the threads.
if at all possible use titanium nuts/bolts as they are less likely to vibrate loose.
while you can get the stock dump/cat off without removing turbo, its not recommended simply because the odds are your going to break a stud off which means removing the turbo to fix it.
its fairly straight forward to get the turbo off the ZD30 motor so i won't go through all the "follow your nose" details.
don't forget to unbolt the oil drain before undoing manifold bolts.
i left a rear bolt in and a bit of wood under the turbo so the turbo won't fall down and crush the oil tube when you undo the bolts. (especially so if you have the heavy cat still bolted on)
working in a bit of lube can help amazingly well.
AFAIK these have titanium studs which have a nasty habit of grabbing then breaking. hence why you tend to break them off.
once you have got the turbo off, remove any broken studs and clean threads with tap to remove any broken bits still left in.
if at all possible fit new dump pipe on while turbo is out of the vehicle. it can be done while turbo is in there but getting to one of the rear bolts is very tight.
odds are you will break a stud off the turbo-dump pipe when removing the cat hence why its best to do it on the bench rather than in car. remove the broken stud and tap out the threads.
re installation tip...do not tighten the main turbo-manifold bolts up tight, keep them loose so you can line up the drain bolts. once oil drain is bolted in then bolt up turbo.
don't forget to bolt up new dump pipe support bracket. you may have to bend the bracket to suit. it needs to line up spot on. try not to have any tension on it when its all bolted up. this will help stop the dump pipe cracking.
obviously big thing here is your going to do an exhaust upgrade at home is having replacement studs, gear to remove broken studs and clean up the threads.
if at all possible use titanium nuts/bolts as they are less likely to vibrate loose.
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