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Old 05-27-2008, 09:25 PM
dawsonj3 dawsonj3 is offline
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Join Date: May 2007
Posts: 116
Remove the manifold - AND make sure that you remove the overflow hose from the radiator - don't lean on it and break it like I did. Plan on this repair taking most of a Saturday.

Removing the turbo by itself, without the manifold, will be really tough due to the rust weld that forms between the mounting bolts and the underlying studs. I tried PB Blaster, to no avail. I then tried using a propane torch, once again to no avail... I then resigned myself to removing the manifold, which finally worked. After freeing the manifold from the vehicle, I was able to remove the turbo using box end wrenches and a mallet.
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Vehicles Owned:
1983 Mercedes Benz 300D ~ 212,000 miles
2005 Mazda 3 S ~ 96,000 miles
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