Mazda 6 Forums banner

1 - 20 of 27 Posts

·
Registered
Joined
·
5,342 Posts
Discussion Starter #1
I'll be pulling the turbo on my car in order to try and extract a stud that's broken off in the exhaust housing.
I started tonight. I'm in no rush, as I don't drive the car but on the weekends.

I'm curious if anybody has any ideas of anything else I should look at or get into while in pulling the turbo mani and turbo. Not necessarily for mods, but for maintenance, or just to check up on anything...
I think at this time I will also replace both the clutch slave cylinder and also be swapping powersteering fluid for fresh synthetic fluid while I'm at it.

Thanks for any ideas:
 

·
Registered
Joined
·
3,414 Posts
GT3076? A BNRS1/2/3 would be an easy swap. I really wish you had another turbo to put in there, even if it was just the BNR S1 to add a little pep and get rid of the smoke. I have no other useful info, lol. Good luck with the job though. Taking your time is the way to do it. It would be great if you could take some pics please!!!
 
  • Like
Reactions: IHeartGroceries

·
Registered
Joined
·
944 Posts
I would most def. check for any play in the turbo turbine shaft. Clean it out (any residue, espeically if you are smoking). Look on the motor where the mani attaches to see if any carbon blow out is present (good indication of the mani seal leaking). Thats all I can think of. Good luck w/ stud retreival.

-Andy-
 

·
Registered
Joined
·
3,660 Posts
if your diff leaks it makes it 10x easier to top off with no turbo back there.
 
  • Like
Reactions: IHeartGroceries

·
Registered
Joined
·
238 Posts
I'll be pulling the turbo on my car in order to try and extract a stud that's broken off in the exhaust housing.
I started tonight. I'm in no rush, as I don't drive the car but on the weekends.

I'm curious if anybody has any ideas of anything else I should look at or get into while in pulling the turbo mani and turbo. Not necessarily for mods, but for maintenance, or just to check up on anything...
I think at this time I will also replace both the clutch slave cylinder and also be swapping powersteering fluid for fresh synthetic fluid while I'm at it.

Thanks for any ideas:
EGR solenoid and tube.... it was so clogged up on the wifes CX-7 that it effected how it ran...in addition to throwing a cel now and again for EGR flow....
 

·
Registered
Joined
·
3,414 Posts
EGR solenoid and tube.... it was so clogged up on the wifes CX-7 that it effected how it ran...in addition to throwing a cel now and again for EGR flow....
Good to see you around Steve. Where is the EGR solenoid? I've had the tube out a couple of times, but never paid attention because I wasn't looking for it :/ I'm assuming it's at the end near the firewall obviously. I hope you have some notes from your fmic install, because I want to do a custom like that come spring :)
 
  • Like
Reactions: IHeartGroceries

·
Registered
Joined
·
5,342 Posts
Discussion Starter #8
Steve, you whore. Come give me a hand.
 

·
Registered
Joined
·
238 Posts
Steve, you whore. Come give me a hand.
I'm on my way you useless wench...........




And doogie.... the solenoid is on the drivers side corner of the exhaust manifold. It wasnt to hard to get at on the CX-7... I looked at my car its a LITTLE more tucked in but still dont look to bad... the biggest PIA is getting the EGR tube off (but you've done that) IIRC there are 4 8mm head screws that hold it on. believe it or not, at least in my case, they came out fairly easy. One work of caution, there is a very thin metal gasket between the manifold and the solenoid, keep an eye on it cuz if you drop it it tends to land in VERY unaccessable places..... not that i would know ANYTHING about that.....

as for the FMIC... yeah i can prolly walk you through it...
 

·
Registered
Joined
·
5,342 Posts
Discussion Starter #10 (Edited)
Just want to update.
It's taken me a week, but I've pulled the hood, battery, tmic, intake, DP, and the turbo manifold, with all of its miserable heat shields. And despite the horror stories, it was a breeze pulling the mani, except for one part. There's a little tab at the bottom of the mani flange that wraps around one of the turbo oil lines for support. Yeah, that little 8mm bolt about had me set the entire garage on fire, with the car in it.
Anyway, the turbo is freestanding now, save for the oil and water lines and the mounting bracket, which I will deal with tomorrow.

**EDIT**
Oh! And I lol'd when I saw only 2 studs holding my DP to the turbo. No wonder I could very clearly hear the roAr of a wastegate at WOT. zomg lolz.
There's one stud that's broken, so there should be 4 working studs. I'm guessing that the DP to car frame rattle that I have is so intense that it loosened and backed out the other nuts AND studs over the past year and a half.
 
  • Like
Reactions: TiGraySpeed6

·
Registered
Joined
·
5,342 Posts
Discussion Starter #11
Got the bastard ass turbo off. Not a huge delima, except for the bottom oil pipe, which I'd guess is the return, and another mounting tab on the bottom of the compressor side supporting a black pipe. That was a morherfucker. And the water in tube fought a little. But, not bad. I see the reinstallation as being a bigger pita.

There's about 5/8" of the broken stud sticking out from the turbine housing. I tried to extract it with some PB Blaster, a heat gun and a pipe wrench. Got a good bite on the stud with the wrench, but just don't have the strength. My 150 just doesn't have it. Lol!!
Now, I'm going to take it to an exhaust shop this week to see if they can tack on a nut onto the stud and just wrench it out. Don't see why that wouldn't work.

Anybody have any more ideas for me to try? I'm heading out of town in the morning. So, I have tonight to keep trying.
 
  • Like
Reactions: MicaBlackMS6

·
Registered
Joined
·
164 Posts
small butane torch
 
  • Like
Reactions: IHeartGroceries

·
Registered
Joined
·
5,342 Posts
Discussion Starter #14
Hmmm...I have a little throw-away torch I was sweating copper with at our new office at work. Well...it belongs to the company, but I can use it.
If I put a torch on it, what would I use to extract it?
 

·
Registered
Joined
·
164 Posts
Spray the crap out of it with PB blaster torch it then get vise grips on it as TIGHT as you can
 
  • Like
Reactions: IHeartGroceries

·
Registered
Joined
·
238 Posts
Got the bastard ass turbo off. Not a huge delima, except for the bottom oil pipe, which I'd guess is the return, and another mounting tab on the bottom of the compressor side supporting a black pipe. That was a morherfucker. And the water in tube fought a little. But, not bad. I see the reinstallation as being a bigger pita.

There's about 5/8" of the broken stud sticking out from the turbine housing. I tried to extract it with some PB Blaster, a heat gun and a pipe wrench. Got a good bite on the stud with the wrench, but just don't have the strength. My 150 just doesn't have it. Lol!!
Now, I'm going to take it to an exhaust shop this week to see if they can tack on a nut onto the stud and just wrench it out. Don't see why that wouldn't work.

Anybody have any more ideas for me to try? I'm heading out of town in the morning. So, I have tonight to keep trying.
Well IF.... and thats a big if .... you were a REAL man... you would just spin it out with your fingers..... otherwise.... sounds like PB a torch and borrow some muscle from someone.....
 

·
Registered
Joined
·
1,256 Posts
You want to torch the housing, not the stud. The idea is to heat the cast iron on the turbo enough to allow the the stud to be unthreaded. Use some vice grips - not your fingers!
 

·
Registered
Joined
·
5,342 Posts
Discussion Starter #18
[/IMG]

Fail. Goddamnit I'm pissed. Taking it to a machine shop now.
 

·
Registered
Joined
·
944 Posts
if you have a screw extractor (in the case a bolt extractor) you could use it (can get a set from craftsman for a few duckies) and then just use a drill to take it out. But I guess the machine shop will take care of it for ya.
 

·
Registered
Joined
·
5,342 Posts
Discussion Starter #20
Just want to post a final update.
Ended up just drilling out the stud all the way through.
Didn't bother tapping it. Just put it back onto the car, ran a bolt through the untapped flange hole and fastened a bolt on the other side. Added some distilled water (lost some coolant) and buttoned everything back up. I left off several heat shield, because in all honesty, they are the biggest PITA. I forgot to add the shield that's situated between one of the mani runners and the alternator. I intended to put it back...
Once I get my hands on a used manifold, I'll put that shield back when I go to install the mani.

By the way, the bottom pipe that fastens to the bottom side of the turbo is a motherfucker to get the bolts, and gasket fed through and threaded into the turbo. My God.
 
1 - 20 of 27 Posts
Top