I an about to replace the head gasket on a 92 940 turbo. Compression 100-90-30-40. Any idea how long should it take?

Echoing what Trichard said, I remember having to buy two tools just to get all of the nuts off on the turbo exhaust manifold. One was an offset 13/15mm wrench and I think the other was a set of adaptors to put sockets on the end of box wrenches.

While the head is off consider replacing all coolant hoses, timing belt and tensioner, the accessory rubber mounts, harmonic balancer, etc. depending on their age and condition.

Hope you don't have any broken exhaust studs to deal with.

Brian Mee

92 945T

In thinking back to a HG replacement on a 94 my biggest PIA was getting 2 exhaust header nuts off. Finally found a racheting box end that I was able to get on the nuts.

Randy

One word about dealing with the turbo plumbing. It is possible to pull the exhaust manifold away from the block with the oil drainback pipe still attached to the turbo--but it is not possible (at least I could never do it) to get the pipe back into the hole in the block with the sealing "O" ring straight and intact. I insert the removed pipe into the block and then work on the two flange bolts at the turbo. I would also caution against using any sealer at any of the turbo oil connections---especially silicone as it could squeeze out and block an orifice. -- Dave

"insert the removed pipe into the block and then work on the two flange bolts at the turbo."

Me too.
--
john

Just curious: how many miles on the car? What coolant do you use? Changed regularly?

I just bought this as a project so I don't know a lot of the history. I was told the engine was rebuilt 2 years ago. I found that the heater control valve was missing one male tube was still in the hose going to the heater core.

Took me about two years....

In actual working time or in turn time to complete the job?

For me a couple of years back, it took a few hours (I think) to remove the head. Start by soaking the exhaust studs/nuts over several days, then give each nut a couple of solid taps to encourage the rust bond to break.

I did not disconnect the intake manifold, simply undid nuts and a few bits and slid it back. Used some wire or string to hold it back a bit. Pulled exhaust manifold, and supported exhaust with a jack. Undid cam cover, head bolts and lifted head off after slacking timing belt. Good time for a new belt.

I took mine to machine shop, checked for flatness, etc, cleaned it up, then put it back on after cleaning block, etc.

Total working time, guessing about 8 hours, but I'm slow. Turn time about a week and half. Hope this helps. Mike

Thanks that does help.

things to watch to for on a turbo hg job:

1. the job is 4-6 hours in total time
2. like said already slide the whole intake back towards the hood hinge once its unbolted AND the accordion hose is removed.
3. unbolting the exhaust manifold is much harder than you think from a quick a look see.

3a. the visible 8 nuts are NOT the problem.
3b. there is a nearly invisible bracket which fastens the bottom of the exhaust manifold to the block with a single bolt on each. this is a BITCH to gain access to as you'll see.

4. the other potential trouble area are the 3 nuts which fasten the header tot he back of the turbo waste-gate. Because of serious heating and cooling these nuts and the studs they fasten to are often really difficult to unfasten causing a stud snap which puts you in a world of hurt. BE EXTRA CAREFUL HERE.

the rest of the job is what you see is what you get with one more exception. replace the two small hoses only found on the turbo model. they are always overlooked and when they fail your engine fails with them.

they are part numbers: 9161383 and 9161384

I don't undo the three nuts which hold the head pipe to the turbo wastegate housing. I undo the hard to reach nut from under the exhaust manifold, and put a floor jack under the head pipe, and lift it just a little. If you lift too much, you'll have to deal with the o-ring at the bottom of the turbo oil drain tube. With the intake manifold removed (of course), the head can be tilted up on the left side and slid up and over the sleeves which position the head gasket.

I don't undo the turbo oil supply line.
--
john

hi john

i have done a few turbo hg using your method but found the stud length on the exhaust manifold was a bit too long making for a very difficult head installation.

it does save time if it can be done in this manner