Help: Replacement K03 turbo (exhaust manifold) not fitting

[trj]

Hi everyone. I had my B7 parked for 3 months now because of a blown turbo(hopefully). Being extremely busy, I have been working on and off on replacing the turbo since then. @mec has helped me a lot in getting it removed and I'd like to save him from helping me again to get it installed. He has been extremely helpful and I owe him a lot of beers.
Yesterday, I had a little free time so tried to put the replacement turbo(I bought from a member here). I am having problems where the exhaust manifold is supposed to slide in to the groove on the engine. I have tried removing, making sure the grooves line up and reinserting the exhaust manifold into the groove many times. All the lines are routed correctly under the car and there is nothing blocking it.

I borrowed the following picture from another DIY. But I am not able to insert the exhaust manifold into the groove outlined by the green line. I even tried hammering it in with a rubber mallet. No go. Is there any tricks to slide the exhaust manifold inside that groove?It goes in slightly, but doesnt slide down. Any help is greatly appreciated.
turbo.jpg

[Audibot]

I recall having a similar problem... I had to do something to essentially "pull" the engine towards the driver's side to create a bit more room.

[mec]

Still haven't gotten it installed!!!!! Lol if you are struggling with the tight tolerances you can double nut the studs and pull those out, should make it easier to fit the mani


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[trj]

I recall having a similar problem... I had to do something to essentially "pull" the engine towards the driver's side to create a bit more room.

Hmmm, I didnt think of it. I will try it tonight. I hope engine has enough give to move by hand? My motor mounts are shot too :)
Just need to install the turbo and sell/trade the car in. I am tired of looking at it parked for 3 months.

Any other suggestions? Anyone?

[trj]

Still haven't gotten it installed!!!!! Lol if you are struggling with the tight tolerances you can double nut the studs and pull those out, should make it easier to fit the mani


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Yah dude. I was travelling every weekend for last 3 weeks. Yesterday was the only day I was a kind of free and decided to give it a go. New job and a lot of travelling has left me with very little time. During the time my bike got stolen from my apartment and I bought a couple of bikes to build, as if I didnt have enough on my plate

[SimbadCA]

Sorry to hear you're have a tough time.




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[billyhoyle]

If you can't move it by hand try a jack from below (on the oil pan, protect it with wood). It should have some give, especially if your motor mounts are shot.

[Avant4me]

The bottom 4 nuts in your picture that hold on those two support bars....loosen them up and it will drop on in

[trj]

If you can't move it by hand try a jack from below (on the oil pan, protect it with wood). It should have some give, especially if your motor mounts are shot.

Good idea. Will go for it if I cant move the engine as is.

The bottom 4 nuts in your picture that hold on those two support bars....loosen them up and it will drop on in

I wanted to go that route, but I dont see any space to tighten all 4 of them once the tubro is in. Is it even possible to tighten them once turbo is in its place?

[Avant4me]

I wanted to go that route, but I dont see any space to tighten all 4 of them once the tubro is in. Is it even possible to tighten them once turbo is in its place?

Yes there definitely is.
1/4" drive with extension and a box wrench will get the job done nicely. I did have to bend the heat shield near the turbo outlet/vc a little bit to give some extra clearance and make it easier.
I just did my ko3 replacement two months ago and despite instructions saying you don't have to it made life soooo much easier and got it in.

[trj]

Yes there definitely is.
1/4" drive with extension and a box wrench will get the job done nicely. I did have to bend the heat shield near the turbo outlet/vc a little bit to give some extra clearance and make it easier.
I just did my ko3 replacement two months ago and despite instructions saying you don't have to it made life soooo much easier and got it in.

Followed your advise and loosened those four nuts. With a little leverage turbo slid in. Now I have no way to tighten those nuts. Lol. Tried for two hours, can't reach the inside nuts, stripped one of the nuts on the outside. Hmmm. I'm thinking to leave them loose. I may have a huge exhaust leak if I leave them loose. Haha.


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[Avant4me]

Followed your advise and loosened those four nuts. With a little leverage turbo slid in. Now I have no way to tighten those nuts. Lol. Tried for two hours, can't reach the inside nuts, stripped one of the nuts on the outside. Hmmm. I'm thinking to leave them loose. I may have a huge exhaust leak if I leave them loose. Haha.


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Did you try from under the car?
It really wasn't that hard to get to them and snug it up. 1/4" drive + extensions and a ratcheting box wrench is what I used. It does take a bit of bending and working your arm around but it's doable.

Good lighting definitely makes things easier too!

[trj]

Did you try from under the car?
It really wasn't that hard to get to them and snug it up. 1/4" drive + extensions and a ratcheting box wrench is what I used. It does take a bit of bending and working your arm around but it's doable.

Good lighting definitely makes things easier too!

Yah, I ran out of day light so didn't work from under the car. Coming weekend now. Haha. The only time I get is on weekends. So, this project has been taking forever.

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[aluthman]

The bottom 4 nuts should not have been loosened. You will have an exhaust leak if they aren't tight. The turbo WILL fit with those nuts tightened, trust me. You just have to get the correct angle.

[trj]

The bottom 4 nuts should not have been loosened. You will have an exhaust leak if they aren't tight. The turbo WILL fit with those nuts tightened, trust me. You just have to get the correct angle.

If I tighten those nuts after the turbo is in place, is there a chance of leak? I have no idea how I will tighten them but I plan to go from bottom next weekend. I tried to push that turbo in from every possible angle for many hours hence had to go with loosening those bottom nuts.


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[aluthman]

If you can tighten them with the turbo in place, you should be fine.

[deusilan]

If you can tighten them with the turbo in place, you should be fine.

Just did that yesterday. I couldn't remove the turbo without loosening the 4 bolts. A socket will get the left nut loose and the rest have to be done with a fixed key. Wasn't hard at all, just keep trying. Finished my turbo install today, yes in the rain, but I got my baby going

[trj]

Finished installing the turbo. The bottom four nuts were accessible by some creative use of wobble extensions. Filled up the lost fluids and tried to start? Battery flat. Jump started it. A lot of smoke from the exhaust manifold and tail pipes. I hope it was just the remaining oil being burnt. Drove around the block. Tires had very less air due to car being sitting for almost four months. Didn't push it too hard. I am just glad it's over. Got cel as well but was too tired to even check what the light was about. Still getting a little smoke out of the exhaust manifold side. Probably exhaust leak. Will fill up air in the tires and check for codes tomorrow.

Will start pulling out the retrofits and mods before putting it up for sale.

Thank you everyone for your suggestions. And special thanks to @mec for helping me out when I couldn't figure what to do.


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