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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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New 1993 940T Replace Exhaust Manifold Gaskets...Remove Turbo? [900]
posted by  AVL940T  on Fri Sep 20 13:29 CST 2019 >


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