So I managed to squeeze my turbo in this weekend. What a nightmare!...
I have done this job a thousand time in the past and each time it was cake. But this time, for some reason, I had the worst experience of all time and it seemed the mechanical Gods were not smiling upon me this day. What should have taken me 3 hrs to do ended up taking me 12 hrs.
Issue number one was when I began removing the turbo. One of the studs in the up pipe was seized and it snapped. Of course I spent a good deal of time drilling it out and re-tapping it.
Issue number two was fitting the new turbo to sit properly on the up pipe. It just wouldn't sit flat no matter what I did. I finally found the obstruction to be the bottom water pipe hitting the block, so I had to bend it up and out of the way. Over all I had to shoe horn the thing in. I attribute this to a very large housing turbo in a stock location. I finally managed to get it in and now it was time to fit the intercooler....
Which brings me to issue number three. For the life of me I couldn't get this thing to go on. Again I have done this quite successfully on a number of occasions but this time it just didn't want to cooperate. Ultimately I had to fit the silicone coupler to the turbo first and secure it, then move the intercooler into the other end of the coupler. To tighten it I was able to reach under and get a stubby wrench in there. Once the bottom coupler was in place and secure I could concentrate on the throttle body coupler.
Issue number four was during the whole process and during my fits of rage, I managed to break off the fitting on the reservoir tank that supplies the turbo with coolant. You can see, by the photo below, my solution for repair as I used a 1/2" NPT hose barb and some JB Weld. The unfortunet thing about that was I had to wait over night for it to dry.
(((Sigh)))