The gasket between the turbo and manifold is under the turbo section of that particular site, #9113937. They usually don't go bad unless it's really old or the studs aren't tight.

While you're looking at the whole thing, chances are pretty good that the reason the exhaust manifold gasket's leaking is that at least one of the studs is either broken (more likely) or missing, if you're lucky.

It is possible to remove the exhaust manifold with the turbo in place, but it's a pain in the butt, and you'll need to loosen the bracket that holds it in place and gently push it down a tiny bit, to clear the studs that are in the turbo body. IIRC, the WIS says to take the exhaust manifold and turbo out as a unit, which in retrospect, might actually be easier. Who knew?! In the meantime, use plenty of penetrating oil on the turbocharger mounting studs before trying to get the nuts off.

If the studs are gone, it's pretty easy to put a fresh one back into the head (I think they're M10x1.25 pitch). Otherwise, you'll need to CAREFULLY drill into the stud (use a right-angle drill or right-angle adapter) as to get it straight. Again, if you're lucky, an EZ-out will extract it. Otherwise, once you've drilled it out, tap the hole with the right tap, and replace the stud. I didn't get the lower RH hold drilled straight (it's a tight fit down there!), so I installed a heli-coil into the now-larger hole, and it worked so-so.

A couple years later, when the head came off (went through everything at clutch replacement time), the mechanics sent the head to the machine shop to be re-welded and re-drilled.

Paul
'01 Aero, 260k miles



posted by 65.100.2...

• It was the exhaust manifold gasket folks., turbostud, Thu, 29 Jul 2010 04:28:22
  • manifold stud kit, LesH, Thu, 29 Jul 2010 11:07:24
    • But you still have to get the old studs out!, Noel, Fri, 30 Jul 2010 06:36:53
      • I'll have the head on the workbench, LesH, Fri, 30 Jul 2010 06:41:00
  • what if I bust a bunch of bolts, turbostud, Thu, 29 Jul 2010 09:54:33
    • What's your threshold of pain?, Noel, Thu, 29 Jul 2010 10:29:23
  • Re: It was the exhaust manifold gasket folks., Paul E, Thu, 29 Jul 2010 06:03:10 <-- Viewing This Message
    • Re: It was the exhaust manifold gasket folks., Name Left Blank, Mon, 2 Jan 2017 18:53:35
  • Re: It was the exhaust manifold gasket folks., Gene N , Thu, 29 Jul 2010 05:04:51
    • but i'm not completely removing the turbo... n/m, turbostud, Thu, 29 Jul 2010 05:32:15
      • Re: but i'm not completely removing the turbo... n/m, saabsince 93b , Thu, 29 Jul 2010 06:54:22

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