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02-23-2009, 08:41 PM
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Senior Member
Join Date: Feb 2009
Location: Spokane, Wa
Posts: 146
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1. Disconnect the negative (-) battery terminal (A).
 2. Remove the drain plug (A) and drain the engine coolant.  3. Remove the front muffler (A).  4. Disconnect the breather hose (A), vacuum hose (B). And remove the air duct (C) and air cleaner assembly (D). -------------------------------------------------------------------------------- Tightening torque : Bolt : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) Clamp : 2.9~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.1 ~ 3.6lb-ft) --------------------------------------------------------------------------------  5. Disconnect the intercooler inlet hose (A). -------------------------------------------------------------------------------- Tightening torque : Bolt : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.4lb-ft) Clamp : 4.9~ 6.8N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.0lb-ft) --------------------------------------------------------------------------------  6. Remove the drive belt (A).  7. Remove the turbo control hoses (A).  8. Remove the power steering pump. (Refer to steering group) 9. Remove the steering pump bracket (A). -------------------------------------------------------------------------------- Tightening torque : 19.6~ 23.5N.m (2.0 ~ 2.4kgf.m, 13.4 ~ 17.4lb-ft) --------------------------------------------------------------------------------  10. Remove the exhaust manifold heat protector (A) and turbocharger heat protector (B). -------------------------------------------------------------------------------- Tightening torque : 7.8~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) --------------------------------------------------------------------------------  11. Remove the oxygen sensor connectors (A).  12. Remove the coolant hoses (A) and oil hoses (B) from turbocharger.   13. Remove the turbocharger stay bolt (A) and WCC stay bolt (B). -------------------------------------------------------------------------------- Tightening torque : A: 49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.1 ~ 39.8lb-ft) B: 8.6~ 27.4N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.2lb-ft) --------------------------------------------------------------------------------  14. Remove the exhaust manifold & turbocharger assembly (A) and gasket. -------------------------------------------------------------------------------- Tightening torque : 49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.1 ~ 39.8lb-ft) --------------------------------------------------------------------------------  
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Hyundai Salesman. DSMtuner. Last edited by 96gsx; 02-23-2009 at 08:51 PM.. |
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02-23-2009, 08:53 PM
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His Majesty the King
Join Date: Nov 2008
Location: in the desert...you can't remember your name...
Posts: 1,761
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that was a lot of work for getting the turbo off that little 4 banger with so much engine room...hmmm...
j/k they make it sound way more complicated than it is.
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THEN 2003 Tiburon GTV6 pkg 3 - CAI, Tails, Custom Dash, Custom Audiobahn Stereo in place of rear seats and half of trunk NOW 2005 Tiburon SEV6 - built, boosted, blown (only once though, and I fixed it) NGM Turbo, Mussa Dual, +a whole lotta goodies 2005 Tiburon GTV6 (STi Blue) Fully Built, NGM Assassin MP90 Supercharger pushing 10psi, all supporting mods, etc. 2007 Kawasaki Ninja ZX-6R - Full akra exhaust, BMC filter, PC3 USB, -1/+2, jumper mod, Power 2CTs, 0-60 in...faster than u. 
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02-23-2009, 09:42 PM
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Member
Join Date: Apr 2008
Posts: 81
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yeah the service manual for my car specifies something like a 15 man hour process for heater core replacement. I can do it in under 2 hours
 engineers are completely apalled by the idea that brackets and hoses can be bent out of the way and that you dont always have to take part A off to get to part B. |
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02-24-2009, 02:59 AM
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Member
Join Date: Feb 2009
Location: Towson, MD
Posts: 78
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Ahhhh, a fellow DSM tuner.
Doesn't look all that difficult. Pulling turbos on a DSM was a piece of cake. Though, don't think I've ever had to remove drive belts to do a turbo swap. Live and learn !
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2008 Evo X GSR 2007 Civic Si Sedan (DD) |
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02-24-2009, 07:24 AM
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.:EX 300WHP TIB OWNER:.
Join Date: Feb 2009
Posts: 961
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Yea.. this car did look like modding would be easy but with all these complex diagrams popping up..maybe not so simple
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02-24-2009, 08:03 AM
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Moderator
Join Date: Apr 2008
Location: Wichita, KS
Posts: 7,444
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well, I am sure that those steps would never be all entirely necessary if you hadn't seen this first :laugh:
This is the "proper" way, and honestly, the service center at the dealership had better follow those steps to the 't', but for mods... yeah, just pull it out, haha.
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02-24-2009, 08:17 AM
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Member
Join Date: Apr 2008
Posts: 81
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well of course whenever i work on one of my cars, if i take a part off and can see no useful purpose for it, it doesnt go back on. things like engine covers, extraneous brackets, and in the case of older cars like mine, emission control devices :P makes it alot easier to work on next time.
head gasket on a stock merkur can take most of the day. i can do mine in an hour. |
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02-24-2009, 08:55 AM
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Banhammer power activate!
Moderator
Join Date: Nov 2008
Location: Greenwood, SC
Posts: 7,670
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Quote:
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02-24-2009, 02:40 PM
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traction control off =]
Join Date: Aug 2008
Location: Philly
Posts: 1,258
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Quote:
 that was awesome
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"I downshift next to hybrids so they can hear me killing the enviroment  "Now:***Karussell White 2.0T Track*** -Superdrift Intake -HKS BOV -MXP 3" turbo-back Exhaust -Beyond Redline Stage 2 
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02-24-2009, 05:07 PM
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Senior Member
Join Date: Feb 2009
Location: Chapel Hill, North Carolina
Posts: 434
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02-24-2009, 05:12 PM
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Flesh's Henchman
Join Date: Dec 2008
Location: Pittsburgh, PA
Posts: 665
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Quote:
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NOW: 2005 Ford Ranger SuperCab (Red) 4.0L V6 LATER: 2011 Genesis Coupe 2.0T Premium (Karussel White) Quote:
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02-24-2009, 06:21 PM
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Flesh's Henchman
Join Date: Dec 2008
Location: Pittsburgh, PA
Posts: 665
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NOW: 2005 Ford Ranger SuperCab (Red) 4.0L V6 LATER: 2011 Genesis Coupe 2.0T Premium (Karussel White) Quote:
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02-24-2009, 08:03 PM
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Senior Member
Join Date: Feb 2009
Location: Chapel Hill, North Carolina
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02-24-2009, 10:03 PM
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Master Member #518
Join Date: Nov 2008
Location: gencoupe.com
Posts: 2,753
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I read up to step 5, and then thought, Ok, next is take off turbo right. Ok, next, Ok, next. C'mon! take off turbo yet... then, step 14 hit. sheesh!
I'm sure it's more like 5 major steps in real life, and you forget the "unplug little hose" part.
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For Sale: Brand New Injen Cold Air Intake for 3.8 V6, never opened, $280picked up, pm me. "...this isnt a tib. the 3.8 will always be a better engine in stock form, and with boltons, and with a turbo/bigger turbo..." 4TGEN "My [blah blah blah] was a beast, but I don't live in the past..." Hank |
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Removing Turbo
Save the polar bears. 
