Turbo replacement questions

[Colepidd55]

Found out over the weekend that my K04 is toast and I'm replacing it with a rebuilt one. I just have a few questions about the install that I couldn't find.

1. I've bought new studs and nuts for the downpipe/mani to turbo connections, as well as a new exhaust mani gasket. I'm just wondering if I will be needing anything else other than those?
2. After the install, does the turbo need to be broken in?

I'm pretty mechanically inclined, but I've never done anything to this extent before. It seems to be pretty strait forward.plus, I can just look at how to's for other turbo installs and just reverse the removal of the K04.BUT, I thought I'd ask so I don't end up killing my new turbo.

any help would be great!

[Turbo_Steve]

Don't forget the gasket for the oil return and you should replace the oil feed copper washers(2) and the coolant pipe washers (4) - Just take your time and be careful as you go otherwise.

[jdmage_mx5]

You will need new coolant drain, coolant feed, oil feed crush washers and an oil drain gasket.

Depending on the milage of your car you can probably get away with applying copper spray to the exhaust gaskets and reuse them.

[Colepidd55]

Where's a good place to get those gaskets and washers?

[Turbo_Steve]

You can get the gaskets from edge autosport - Probably best bet is mazda on the washers

[Colepidd55]

thanks for the info guys. I'm searching mazdapartonline and I'm not finding those washers..anyone got a part #?

[Colepidd55]

no one?

[jdmage_mx5]

1 qty Oil Drain (lower pipe) to Turbo Gasket - L3K914293
2 qty Oil Feed (upper pipe) Crush Washer - 995621200
4 qty Coolant inlet/outlet Crush Washer - 995621400

All parts can be found here: Link

[HawkeyeGeoff]

Originally Posted by jdmage_mx5 1 qty Oil Drain (lower pipe) to Turbo Gasket - L3K914293 2 qty Oil Feed (upper pipe) Crush Washer - 995621200 4 qty Coolant inlet/outlet Crush Washer - 995621400 All parts can be found here: Link

Look at this guy right here, being all helpful and stuff! Kudos!

[jdmage_mx5]

I just got done spoon feeding my 3 year old son who was acting helpless. I guess I was in the groove. LOL.

[Colepidd55]

Originally Posted by jdmage_mx5 1 qty Oil Drain (lower pipe) to Turbo Gasket - L3K914293 2 qty Oil Feed (upper pipe) Crush Washer - 995621200 4 qty Coolant inlet/outlet Crush Washer - 995621400 All parts can be found here: Link

Thank you!

[MSMS3]

No special break in. Just avoid full boost for the first 100 miles or so. It would be good to fill the turbo oil inlet pipe with oil to avoid it running dry the first few seconds after it starts until it gets oil from the pump. Some rebuilt turbos come with some temporary lube on the internal center shaft bearings.

I just had mine rebuilt by Work Turbochargers (turborepair.com) in North Alabama, and it came back with some temporary internal lube.

[09TrueRedGTX]

Originally Posted by MSMS3 No special break in. Just avoid full boost for the first 100 miles or so. It would be good to fill the turbo oil inlet pipe with oil to avoid it running dry the first few seconds after it starts until it gets oil from the pump. Some rebuilt turbos come with some temporary lube on the internal center shaft bearings. I just had mine rebuilt by Work Turbochargers (turborepair.com) in North Alabama, and it came back with some temporary internal lube.

You could also hold the gas pedal to the floor while cranking the engine. This will allow oil to flow into/out of the turbo, without actually starting then engine. Do that 3 times for 5 seconds each, and you should be good to go.

[Killer95GT302]

Originally Posted by 09TrueRedGTX You could also hold the gas pedal to the floor while cranking the engine. This will allow oil to flow into/out of the turbo, without actually starting then engine. Do that 3 times for 5 seconds each, and you should be good to go.

What he said - you'll know its pressurized when the oil light turns off.

The best tip I can give is take your time, especially if this isn't your primary car. Don't fall into the forum mechanic hours estimate trap. Make sure you clean up all mating surfaces real good. Last thing you want to do is rip it apart again to fix an exhaust leak.

[superman]

Did you say exhaust manifold gasket? I recently did a bnrS3 swap and did not remove the exhaust manifold. I would recommend this approach.

Freeks BNR install

This way you don't need that gasket, and ideally the install will go faster.

[Colepidd55]

yeah, I assumed it would just be easier to take off the manifold to get the turbo out. I guess all the how tos' i read said to do it. But, I'll try without taking out the manifold first.

It's my primary car, but I've been driving a buddies truck. I'm itching to get this done, but I'll make sure to take my time. I was talking to a friend who does a lot of work on VWs and he told me to do an oil change after 100 miles. I'm due for one anyways, but i was wondering maybe I should do it before I swap it? I have about 3k-4k on the oil right now.

[CFI2008]

Don't bother taking off the exhaust manifold or even the turbo bracket. The bottom two bolts on the bracket would not break so I just took the one that held the turbo on off and removed the turbo to mani studs using the 2 but method m10 1.5 nuts. Skids right out drivers side.

[jdmage_mx5]

So yea the k04 does slip out the driver side but for as easy as it is to remove the manifold vs wiggling it around the egr and brake booster area I would go with removing the manifold if it were me. I've done about 5 swaps on various speeds and taking the manifold out is my preferred method.

On the nuts near the turbo for manifold to block just break loose and use a ratcheting wrench.

For this last swap I took out the windshield trim on the bottom and I immediately regretted not doing it on the other swaps. I would rather take more bolts off in a relaxed manner vs getting frustrated with lack of space to work in.

[CFI2008]

I just did this swap with a bnr. You remove the break boost hose and remove the EGR and no issues taking it out. Very little wiggling required

[qkrthnu2]

Originally Posted by Colepidd55 Found out over the weekend that my K04 is toast and I'm replacing it with a rebuilt one.

Am I missing something? I didn't think there were any Mazdaspeed K04 turbos that could be rebuilt? Make sure you're not just being sold a used turbo, that would suck.

My install tips:

1. Remove your hood
2. Remove the cowl

Those two things will take ~15-20min and make the job SOOOOoooooo much easier.

[g00s3y]

Originally Posted by qkrthnu2 Am I missing something? I didn't think there were any Mazdaspeed K04 turbos that could be rebuilt? Make sure you're not just being sold a used turbo, that would suck. My install tips: 1. Remove your hood 2. Remove the cowl Those two things will take ~15-20min and make the job SOOOOoooooo much easier.

Why would it not be able to be rebuilt? I rebuilt mine, and put a new stock wheel on it for ~$110, cheaper than buying a new one.

And neither of those things need to be removed to install the turbo. Jack up the car, remove the DP, unbolt it from from above, and take it out from below. Much easier than trying to get it from the side.

Have fun with the turbo bracket though, be prepared for many beers and curse words when trying to remove it.

[qkrthnu2]

Originally Posted by g00s3y Why would it not be able to be rebuilt? I rebuilt mine, and put a new stock wheel on it for ~$110, cheaper than buying a new one. And neither of those things need to be removed to install the turbo. Jack up the car, remove the DP, unbolt it from from above, and take it out from below. Much easier than trying to get it from the side. Have fun with the turbo bracket though, be prepared for many beers and curse words when trying to remove it.

RE: Rebuilding the K04, I stand corrected. I have no idea how I got that idea stuck in my head. Maybe the idea of "not worth rebuilding" morphed into "can't be rebuilt" or something like that.

I forgot how easy you MS3 guys have it with all that room behind the engine. No way are you getting the turbo out the bottom on a MS6.

[Colepidd55]

Well, I got it replaced today...Holy shit I'm never doing that again. took me 8 hrs strait to do it. First time I've ever taken my car apart that much. I'd say the most pain in the ass thing was that turbo bracket in the back and the coolant return line... Fucking coolant everywhere.

Turbo came out the intake side pretty easily though. I'm happy I didn't take the whole exhaust mani out.fuck that noise.

[Raider]

You could have clamped the coolant line with vise grips first.

[Colepidd55]

Originally Posted by Raider You could have clamped the coolant line with vise grips first.

Yeah, didn't think of that till after it was in my face..

[Raider]

Originally Posted by Colepidd55 Yeah, didn't think of that till after it was in my face..

That's what SHE SAID!

Zing.

[Colepidd55]

Originally Posted by Raider That's what SHE SAID! Zing.

ya got me.

[paxtonschwendner]

hate to revive an old thread, but some searching brought me here. i'm going to replacing my K04 (after a rebuild) and was looking for a parts list of things that need, and should, be replaced. i have 140k on her so i don't mind replacing old parts!

[breakfstincluded]

Originally Posted by paxtonschwendner hate to revive an old thread, but some searching brought me here. i'm going to replacing my K04 (after a rebuild) and was looking for a parts list of things that need, and should, be replaced. i have 140k on her so i don't mind replacing old parts!

Did you read any of this thread?

[Raider]

I did, and did not see any how-to. So...

[jdmage_mx5]

Seems like last time I did a turbo swap I got on here looking for a detailed parts list but did not see one (oil feed washers, oil drain gaskets, manifold to turbo gaskets, etc). If it's here then it is buried and should be brought from the dead so Google will display it.

[paxtonschwendner]

yes, I read. the parts were for a gen2 ms3. I have a ms6. I don't think the parts are the same, but then again, I have no idea. that's why I asked.

[breakfstincluded]

Originally Posted by jdmage_mx5 1 qty Oil Drain (lower pipe) to Turbo Gasket - L3K914293 2 qty Oil Feed (upper pipe) Crush Washer - 995621200 4 qty Coolant inlet/outlet Crush Washer - 995621400 All parts can be found here: Link

Can you clarify Paxton?

Do you mean you are rebuilding a K04? Or buying another K04 entirely? Or replacing your K04 with a different turbo?

I'm compiling a parts list for replacing my dying K04 soon. I used the link above to view all washers and gaskets I can replace while I'm doing the turbo switch.

Besides what was listed above by jdmage, I'm also getting a new Turbo-Downpipe gasket and Manifold-turbo gasket which can also be found through the above link, many re-use them also.

If your purposes are similar to mine then I believe it's the same for MS6/genwon/genpu, I have a genwon. Unless someone can correct me, all involved parts, engine/manifold/k04 are the same.

Or are you looking for a list of parts to rebuild a K04 turbo itself?

[jdmage_mx5]

Damn @breakfstincluded; is on it. I knew I posted them somewhere a while back but I have terrible memory and was not in a position to look.

Awesome work.

As stated the same gaskets are needed whether MS6 or MS3 unless you are doing something extremely unnecessary.

[paxtonschwendner]

I was more or less looking for confirmation that the parts needed are, in fact, the same regardless of generation. I'm having my K04 rebuilt (or maybe BNR stage 1 ) so I was just looking for the gaskets, washers, etc. that should be replaced. it was a pain in the dick to get all that apart so I wanna get it right the first time!

[breakfstincluded]

Originally Posted by paxtonschwendner I was more or less looking for confirmation that the parts needed are, in fact, the same regardless of generation. I'm having my K04 rebuilt (or maybe BNR stage 1 ) so I was just looking for the gaskets, washers, etc. that should be replaced. it was a pain in the dick to get all that apart so I wanna get it right the first time!

Cool well, you got'em now. Just use Jdmage's post from earlier in the thread.

The turbo-manifold and turbo-downpipe gaskets are optional, either way I'd personally apply copper gasket as well.

[Design]

Couple more links since I just did mine, most of which are contained within jdmage_mx5's link. Should be the same between the MS6 and Gen 1/Gen 2 MS3 (but confirm the part IDs just in case):
1. DP gasket:
2009 Mazda 3/M Parts - Online Mazda Parts
2. TC gasket to mani:
2009 Mazda 3/M Parts - Online Mazda Parts
3. Water inlet & outlet gaskets (x4):
2009 Mazda 3/M Parts - Online Mazda Parts
2009 Mazda 3/M Parts - Online Mazda Parts
4. Lower oil pipe gasket, turbo side:
2009 Mazda 3/M Parts - Online Mazda Parts
5. Upper oil pipe gaskets (x2 turbo side, x2 block side):
http://onlinemazdaparts.com/parts/20...0pipe%20gasket
6. Lower oil pipe gasket, block side (if removing lower pipe completely):
http://onlinemazdaparts.com/parts/20...&siteid=214264


Turbo removal/install directions:
http://www.corksport.com/support/ins...-6-777-WEB.pdf

^^Yes, they are for the Corksport turbo but the approach is exactly the same.