turbolarry said:The only way I know how is to remove the turbine housing/O2 housing. The CHRA and compressor housing stay put;
With the motor warm/operating temp., raise the car and remove the bottom splash gaurd. Get an O2 sensor socket and get the O2 sensor out before it gets too cold.
Remove the tie bars and drop the downpipe.
Let things cool down a bit more and remove both upper and lower heat shields.
Spray the two front manifold to turbo nuts with PB Blaster. Get under the car and spray the two manifold to turbo bolts from the bottom at the turbine housing. Get a breaker bar and crack'em loose.
Spray the manifold nuts with PB Blaster and with the right extensions crack loose the manifold.
With a 17mm socket remove the turbo's oil feed banjo bolt at the head and don't lose the washer (this will give you more slack for pushing and tugging).
Fully remove the manifold to turbo hardware and all the nuts to the manifold.
With the little tugging and pushing I mentioned before remove the manifold.
Remove the V-band clamp on the turbo (10mm).
With a small hammer, very carefully tap loose the turbine housing/O2 housing. Be very careful not to damage the turbine blades as you pull it up and out.
Spray PB Blaster in the treads of the O2 housing to turbine housing bolts (and 2 nuts). Clamp it down, crack it loose, and seperate the O2 housing from the turbine housing.
Put it back together in the reverse. Torque specs can be found here;
When installing the exhaust manifold (from my '04 manual);
1. Hand tighten all the exhaust manifold mounting nuts.
2. Tighten the M8 nuts (12mm) to 21 ± 2 ft-lb in the indicated sequence.
3. Tighten the M10 nuts (14mm) to 36 ± 3 ft-lb in the indicated sequence.
4. Tighten the M8 nuts again to 21 ± 2 ft-lb in the indicated sequence.
5. Finally tighten the M10 nuts and the M8 nuts to the specified
torque, both in the indicated sequence.
24 ± 4 ft-lb M8
41 ± 6 ft-lb M10
I really wish I had taken pictures of this when I did it last month.