Engine/Transmission (1998.5 - 2002) Turbo pictures---- need advice

[MullinsM]

Please look at the following pictures and give me any advice you can.

Top Pic is the inlet. Appears pretty good. No cracks - fairly sharp vane edges-- some grease type smudging around impellor area.



Middle Pic exhaust. Again no cracking just alot of carbon. Should this be cleaned and if so how?



Bottom Pic exhaust manifold to turbo inlet. You can see the gasket impression and from what I am understanding about porting the area inside the gasket impression should be removed and tapered back 1"-1 1/2". This area should be as smooth as possible on both the exhaust manifold and the turbo. Am I correct?



Added Pic#4 which is after porting the turbo

Added Pic#5 this was my exhaust manifold. Those are thru wall cracks and when I got it off it was cracked all the way around into the bolting surface.

Replaced it with an AST 3 piece and did a little porting on the turbo mating flange. I don't have any experience with any other manifold brand. This manifold is well built but it was not an easy job. Some of the hardware with it was wrong. The bracket for the heater hose did not mate up. The center section is held to the head with cap screws needing an 8mm hex head wrench.

Took 10hrs to dismantle, port and reassemble. Disassembly and porting was by myself with son getting home and helping with assembly.



Thanks for any help

Mike

 

[darkhorse]

I've been trying to send some photos but for some reason I can't get them to load here or in e-mail. My internet connection has been troublesome today. You have the right general idea. No need to clean the carbon. You do need to leave about 1/8 of material on both outside edges of the manifold ports. Otherwise the metal is too thin by the recesses for the mounting bolts. Just scribe a vertical line 1/8 inch from the gasket impression on those sides between the bolt hole & stud. That isn't required on the turbine housing. I'll keep trying to get the photos to you.

 

[darkhorse]

I started with a used manifold I got from another TDR member on the classifieds. It came from Florida which explains the rust in the first photo. The right port is about done & the scribe lines are visible. The second photo showes the turbine housing & the manifold after my Dremel work. It wasn't too time consuming with carbide cutters.