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1993 940T Replace Exhaust Manifold Gaskets...Remove Turbo? 900

I have been postponing this job because of the potential for broken studs and the usual unforeseen. But I am ready to order parts and after reading the FAQ I would like to ask those familiar with the job if it would be helpful to remove the turbocharger.

The FAQ says to "loosen the turbo to down pipe nuts OR loosen the down pipe fixing bolts at the bell housing and transmission, depending on your car". Is this going to give me enough room to get the manifold out of the way and to replace the studs?

I would also like to know of any parts that might be needed besides the gaskets, nuts and new studs. That will certainly depend on whether I remove the turbo.

Thanks.








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    1993 940T Replace Exhaust Manifold Gaskets...Remove Turbo? 900

    i have done this job on several 93-95 turbo 940's.

    1. the 3 nuts on the back of the turbo to the header downpipe can be easy/hard or impossible to remove without snapping the studs. the incredible heating and cooling at that location can give you real trouble. no way to know until you try but be warned

    2. the 4 nuts on the turbo to exhaust manifold are nasty to remove because access to both lower ones is very very very difficult

    3. imo leave all of them alone unless they need to come off for other reasons

    if you are going to replace ALL 8 studs imo you will have a MUCH easier time and the job will go much faster if you decide to do a head gasket job at the same time.

    hear me out before calling me stupid

    the exhaust side plumbing and flotsam is the hardest part of the job and IF you break even 1 stud you are have to EITHER remove all the turbo side plumbing or remove the head to gain access to replace

    i have perfected a way to do a turbo head gasket in under 5 hours start to finish WITHOUT removing any turbo side plumbing at ALL other than large diameter hoses that obstuct the head or intake manifold from being pull back towards the drivers fender.

    this is how i do this job.

    1. remove all large hoses over the head and connected to the intake manifold

    2. remove 8 intake nuts and pull intake off head and nut holding IAC bracket to manifold ...pull intake toward drivers fender and tie off to hood hinge

    3. disconnect all sensors on that side now and heater core hose to head

    4 remove all 8 exhaust manifold nuts removing those aluminum covers ..you will NOT be reinstalling the alum covers

    5. if you snap an exhaust stud no worries

    6. remove timing belt cover by removing 4 water pump pulley bolts

    7. loosen tbelt tensioner AFTER setting timing to TDC and slip off belt ... using a spring clamp clamp the tbelt securely as it goes over around the inter mediate pulley. pull the inner t belt cover forward carefully towards the radiator so it clears the head

    8. this is the only hard part... you are going to remove the head while the exhaust plumbing is in place. because of the angle of the head downward into the turbo you will need to be creative and just work it loose and off the block. it takes under 30 minutes but be patient, it is a tight squeeze clearing the manifold studs from the manifold holes with the manifold in place. you might try a pry bar between the manifold and head to pry the manifold back towards the passenger fender for a little bit of extra clearance but do not over due it.

    9. remove all the old studs with head on the bench

    9. buy these studs or allen set screws as they might be called note the hex indented at one end

    https://www.ebay.com/itm/ZORO-SELECT-6FE98-Socket-Set-Screw-Cup-M8x1-25mmx60mm-PK10/332055753076?epid=22026471391

    2 packs of these https://www.ebay.com/itm/Socket-Set-Screw-M8-1-25x60MM-Black-Oxide-Coated-5-pack/123479853931

    10. now the head without the studs will go on effortlessly even with the turbo plumbing place

    11. carefully place the ex man gasket in place as you slide each stud into place to thread using an allen wrench. if you tapped each head hole before installing the threading should be simple.

    i suggest 60 mm studs so the exhaust manifold nut is fully covered by a solid stem once you torque it down and no nut is torqued around the indented allen hex hole

    the rest of the job is reverse of removal

    start at 8 in the morning and you ought to be done by early afternoon

    all allen studs are still in place with no breakage of any kind going on 6 years for oldest job and 3 for the newest








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      PS 900

      there is bracket which fixes the ex manifold to the block which is close to impossible to loosen to remove without first removing ALL the turbo plumbing

      in point of fact it WAS THIS bit of the puzzle which prompted me to find a faster more efficient method of doing this job on that car.








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        PS 900

        Thank you very much for the detailed reply. You've given me something new to consider. I knew the job was going to a challenge.








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          PS 900

          if the studs are ok and you have no exhaust leak leave well enough alone

          this is not a job you do because you're bored or want to tinker with your car. there are many easier ways on a 940 turbo you can be useful.

          imo the replacement of the exhaust manifold studs is among the most challenging you can undertake with the engine intact. the simplest thing like snapping a stud can GREATLY complicating what started out as straightforward plan.

          every battle plan looks good until you get punched in the nose








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            PS 900

            I do have an exhaust leak, but I don't think my manifold is cracked. I diagnosed the leak at the gasket with smoke and
            a shop vac on the tailpipe. The studs are okay, 168,000 miles on the car. I was going to replace the studs because it's recommended, but as you say, no need to court trouble.








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      1993 940T Replace Exhaust Manifold Gaskets...Remove Turbo? 900

      I sure enjoyed reading this Ted. Ingenuity combined with real experience. Those long set screws in M6 flavor might have some use around my water pump changes too. Thanks.
      --
      Art Benstein near Baltimore

      "Carefully pry (If this were a Jaguar you would prise)..." -BrickDad







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