2004 Turbo Replacement

[scottmcd]

My son is trying to replace his stock turbo with a stock set up. What is the best way to get the nuts off? Should he pull the exhaust manifold or can it be done without the removal.

Truck has 200k plus on it.

Appreciate the helpful advise.

 

[skull03]

I thought removing the exhaust manifold and turbo together was the easiest route myself. A little heavy but definitely easier to get at the turbo flange bolts.

 

[promisedland]

Carefull use of heat helps stubborn nuts, carefully!

 

[scottmcd]

does this look like an '04 turbo. It doesn't look anything like the stock one I had on my '04

 

[mweiman]

Not sure but I think maybe they are different from an early 04 to 04.5. That turbo looks like it has electric wastegate actuator. Early 04 probably does not.

 

[scottmcd]

Turbo and manifold are out of the truck. The block side nuts are of the turbo housing, the outside 2 nuts wont budge. They have been soak for hours in BP Plaster. Only size wrench that fits is 15mm, although it fills a bit too big. Nothing else comes close to fitting. Any ideas? I really do not want to round them off.

He needs to be at work Monday morning and I got a race to watch tomorrow.

 

[Ozymandias]

Heat them like it is mentioned above.

And yes the Turbo shown above is a 04.5

9/16 wrench doesn't fit?

 

[EricViviano]

I always soak them the day before with Seafoam. I take off the two facing down from below with a long extension and a wobble socket on my 1/2 gun. The other two extra long wrench, sometimes you have to smack it with a hammer.

Now that it's off, heat the nut (this will expand it), then use your impact.

That is the stock turbo.

 

[scottmcd]

Appreciate all the help. Definitely going to give it a little heat and see where we get to. Then new nuts that are a real size.

Just some of the fun buying a used truck, not knowing what may or may not have been done to it.

 

[cerberusiam]

That is a a stock turbo for a 04.5 325 engine, not the 04 305.

Why is he replacing stock with stock? The original bad?

 

[scottmcd]

The stock turbo has alot of play in it. He is a little strapped for cash, so just a stock swap .

How can he tell if the truck is actually a 04.5 instead of an 04?

 

[seafish]

The stock turbo has alot of play in it. He is a little strapped for cash, so just a stock swap ....

FYI--

Some axial (end) play of the turbine shaft is built into the design of the turbo as it allows for oil lubrication of the shaft and journal bearings. In fact, the turbo shaft "rides" on a thin coat of oil between the journal bearings and the shaft as it spins.

Radial play (side to side) in any amount is NOT acceptable.

 

[cerberusiam]

Build date should be on a sticker on the drivers door. If it was was built in 04 it is an 04.5. Also, the engine sticker will tell you the ratings, a 325 is always 04.5.

 

[scottmcd]

I am assuming that is a electronic wastegate actuator that on the front of the turbo. What is the best way to ge5 it off the old turbo and onto the new one?

The truck was built 1/04, so it is a ‘04.5.....

 

[scottmcd]

we found a spec of 32ft/lb for the exhaust manifold bolts. Any idea on the turbo bolts to the manifold?

 

[cerberusiam]

They can be as fun to remove as the flange bolts, a special socket is required IIRC. Doesn't the replacement turbo have one?

 

[scottmcd]

They can be as fun to remove as the flange bolts, a special socket is required IIRC. Doesn't the replacement turbo have one?

It did not come with one. Mainly because he ordered for a 04 not an 04.5.
Truck probably will not run well without having the solenoid installed?

 

[cerberusiam]

The HE341's off an 04 do not have a place for the Solenoid, it is just not there. A resistor to fool the WG programming and the 04 turbo should work the same, just short of boost.

 

[Ozymandias]

Send it back, get the right one.
I think HE351CW should be yours.

 

[scottmcd]

The turbo he got had a spot for the solenoid.

Everything wants back together nicely & no problems so far.

Thanks for all the help .