I have a 94 940 turbo with a leaky exhaust manifold and a unsolvable bad gas mileage problem. I am looking for a tutorial on what I would need to do with the turbo because it needs to be removed to get at the exhaust manifold. Is there anything out there? I might have access to a used turbo as well. It has 100k more miles than mine so might need a rebuild?

 

removing it is a matter of using a whole lot of kroil on the rusty bolts, and swearing a lot. plan on using new hardware when you reassemble.

i can't help you with the turbo rebuild. mine is dribbling a bit of oil into my intake path, but not enough to consume measureable amounts of oil or smoke, just enough to make things oily. I'm sorta of figuring when it gets worse or dies, I'll be buying a full rebuild from a rebuilder, and those are like $700 or something (for the TC05 used on 940s and later 740s).

 

So basically there are no seals or anything that need to be replaced when I remove the turbo? just possibly new bolts and nuts and studs? mine is leaking a little oil.

 

well, there's a bunch of *high* speed bushings and bearing... I actually have a small colleciton of rebuild parts someone gave me as part of a craigslist deal.


(note that is the WRONG turbo for a 740/940... but I think some of those rebuild parts ARE for a Mitsubishi TC05 which is the turbo on a late 740 and any 940).

[do note, even if your car uses a TC05 or whatever, not all TC05 or whatevers are interchangable, there are minor variations in things like EGR porting that have to match... think of TC05 as a family rather than a specific model].

 

Just remember, if you do end up replacing the seals and bearings, they have to be taken out and inatalled in a certain way because the turbo spins between 15,000-100,000 rpm.

 

The most difficult task in rebuilding a turbo is getting it separated. After removal, it may take a weekend of soaking in penetrant to get them to loosen. I use G-Pop Shop I'm sure there are many others but they are extremely helpful and knowledgeable. I tend to stay with merchants who go the extra mile.