I
izzni
Well-known member
My goal wasn't actually to remove the Turbo Outlet. I actually just wanted to put my temp sensor splice in the coolant line that runs to the oil cooler and beyond. However, to get a good view of what I was doing I decided to remove it. After the fact I found that there was enough slack in the coolant line that I could splice it from the muffler area, but I didn't know that in advance.
In case you are wondering, the reason I'm installing a dedicated temp gauge is that I ride my mountain sled on trails in Minnesota about 2/3rds the time. Having to put the gauge in diagnostic mode every time I start up, and then not being able to see the trip unless I restart the sled is stupid. Plus the gauge I'll be installing flashes at a temp you can preset.
In any case, I got the show on the road by removing the hood. I've posted pictures of that before, so I won't include that.
After the hood was off I started working on removing the intercooler. I removed the three hoses that were connected to it along the top. Note that to remove the hose that has that valve on it I needed to loosen the hose clamp that holds the air filter. Here are the before and after:
In addition, you need to disconnect the hose on the bottom of the intercooler:
There are four mounts for the intercooler. The top two are through bolted, and the bottom two are riveted. Remove the top two bolts. Below are pictures indicating where you'll find the nut, and where you'll find the screw (bolt):
In the picture below you can see that the intercooler will now rotate on the axis formed by the bottom two mounts:
In this grainy picture you can see how to remove the bottom two mounts. Since the mounts are riveted on you just need to pull the intercooler spline out of the rubber boot. The mount is riveted to fairly flexible plastic, so it will give reasonably easily:
As you can see, once you have one of the bottom two rubber mounts disconnected it gets really easy to do the other one:
I flipped my intercooler over only to find this disappointment:
I wanted to be able to get two hands in front of the motor in case I needed to remove that coolant hose from the oil cooler, so I needed to remove the bottom exhaust shield that covers the turbo:
Once you have all five screws out you can rotate the thing out under the coolant line that goes to the turbo. It's pretty tight, and you have to bend the exhaust shield a bit. The key is to rotate it counter clockwise as you remove it:
The exhaust shield has 3 screw mounts on the upper shield that the lower shield screws onto. One of them came off and fell down in front of the motor. Here it is after it was retrieved by my trusty magnet:
Look at that beautiful turbo!
Next I removed the exhaust. You start by removing the spring. You'll need a spring puller/specially designed coat hanger for this:
You'll need to position the coat hanger behind the oil return pipes in order to get the right leverage on the spring:
AFTER you've disconnected the pipe sensor, you can remove the exhaust. Pull the bottom of the muffler out, and then slide the whole muffler upwards to remove it:
There's a peice of plastic on the exhaust side of the sled that prevents good access to the nuts that hold the turbo outlet on. Once the exhaust is out of the way you can remove it. The first screw is easy:
The second one is directly inline with the turbo outlet pipe. Fortunately, with the exhaust out of the way the flex joint of the turbo outlet will allow you to get enough clearance to remove the second screw:
Here's the peice of plastic I removed:
And here is the much improved access to the turbo outlet nuts (there are four):
Two of the nuts you can use a universal joint and ratchet. The two others you need to use a wrench. The worst one is the bottom back one. I had to reach through the spot where the intercooler normally is and get a wrench on the nut from the bottom to get it out. Since it required that I basically be humping the front left spindle of the sled and using both hands I wasn't able to get any pictures of the technique I used to get that nut off. It was extremely unpleasant though, and took about 10 minutes. Here's a picture of a much easier to remove nut with the rachet on it:
Someone had a problem with welds in the turbo outlet hanging up their waste gate. My welds look pretty good:
Here's a view of the exhaust impeller and waste gate:
Tomorrow I'm actually going to install my water temp sensor and put it back together, yay!
In case you are wondering, the reason I'm installing a dedicated temp gauge is that I ride my mountain sled on trails in Minnesota about 2/3rds the time. Having to put the gauge in diagnostic mode every time I start up, and then not being able to see the trip unless I restart the sled is stupid. Plus the gauge I'll be installing flashes at a temp you can preset.
In any case, I got the show on the road by removing the hood. I've posted pictures of that before, so I won't include that.
After the hood was off I started working on removing the intercooler. I removed the three hoses that were connected to it along the top. Note that to remove the hose that has that valve on it I needed to loosen the hose clamp that holds the air filter. Here are the before and after:
In addition, you need to disconnect the hose on the bottom of the intercooler:
There are four mounts for the intercooler. The top two are through bolted, and the bottom two are riveted. Remove the top two bolts. Below are pictures indicating where you'll find the nut, and where you'll find the screw (bolt):
In the picture below you can see that the intercooler will now rotate on the axis formed by the bottom two mounts:
In this grainy picture you can see how to remove the bottom two mounts. Since the mounts are riveted on you just need to pull the intercooler spline out of the rubber boot. The mount is riveted to fairly flexible plastic, so it will give reasonably easily:
As you can see, once you have one of the bottom two rubber mounts disconnected it gets really easy to do the other one:
I flipped my intercooler over only to find this disappointment:
I wanted to be able to get two hands in front of the motor in case I needed to remove that coolant hose from the oil cooler, so I needed to remove the bottom exhaust shield that covers the turbo:
Once you have all five screws out you can rotate the thing out under the coolant line that goes to the turbo. It's pretty tight, and you have to bend the exhaust shield a bit. The key is to rotate it counter clockwise as you remove it:
The exhaust shield has 3 screw mounts on the upper shield that the lower shield screws onto. One of them came off and fell down in front of the motor. Here it is after it was retrieved by my trusty magnet:
Look at that beautiful turbo!
Next I removed the exhaust. You start by removing the spring. You'll need a spring puller/specially designed coat hanger for this:
You'll need to position the coat hanger behind the oil return pipes in order to get the right leverage on the spring:
AFTER you've disconnected the pipe sensor, you can remove the exhaust. Pull the bottom of the muffler out, and then slide the whole muffler upwards to remove it:
There's a peice of plastic on the exhaust side of the sled that prevents good access to the nuts that hold the turbo outlet on. Once the exhaust is out of the way you can remove it. The first screw is easy:
The second one is directly inline with the turbo outlet pipe. Fortunately, with the exhaust out of the way the flex joint of the turbo outlet will allow you to get enough clearance to remove the second screw:
Here's the peice of plastic I removed:
And here is the much improved access to the turbo outlet nuts (there are four):
Two of the nuts you can use a universal joint and ratchet. The two others you need to use a wrench. The worst one is the bottom back one. I had to reach through the spot where the intercooler normally is and get a wrench on the nut from the bottom to get it out. Since it required that I basically be humping the front left spindle of the sled and using both hands I wasn't able to get any pictures of the technique I used to get that nut off. It was extremely unpleasant though, and took about 10 minutes. Here's a picture of a much easier to remove nut with the rachet on it:
Someone had a problem with welds in the turbo outlet hanging up their waste gate. My welds look pretty good:
Here's a view of the exhaust impeller and waste gate:
Tomorrow I'm actually going to install my water temp sensor and put it back together, yay!
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