Please note that this is only a guide and may have missing steps and/or tools required.
It should also be noted that this operation is not for the average "home mechanic". Expect to spend about 1 1/2 days to get the turbo assembly out and another 1 1/2 days getting things back together.
The removal of the pre-cat from the exhaust system is the most exasperating part of the job. All of the bolts, nuts and studs on the exhaust system will be rusted and very difficult to remove. Some of the studs will either break or the threads will be damaged, either case resulting in having to also remove the stud, which of course will also be rusted into place :-).
Parts List, (from your favorite Mazda parts dude):
| Qty | Description | Part Number | approx$ |
| 4 | Turbo compressor inlet/outlet gasket | N3A1-13-712 | 10.00 |
| 3 | Turbo oil return pipe gasket, (Type 1) | N3A1-14-293 | 7.00 |
| 1 | Turbo oil return pipe gasket, (Type 2) | N3A2-14-293 | 7.00 |
| 9 | 10mm nut (Downpipe to Turbo and Turbo to Exhaust Manifold) | JE10-40-355 | 4.30 |
| 9 | 10mm stud (Downpipe to Turbo and Turbo to Exhaust Manifold) | NF01-13-708A | 13.70 |
| 1 | 8mm nut (Turbo to Exhaust Manifold) | E5B6-13-461B | 4.00 |
| 1 | 8mm stud (Turbo to Exhaust Manifold) | N391-13-456 | 12.00 |
| ~TOTAL | 170.00 |
The four Turbo compressor inlet/outlet gaskets are a fibre material from the factory, these ones are reusable metal ones. Rumor has it that some where in the '94 year models Mazda changed to the metal ones from the factory. The 10mm studs are the most expensive an you need lots of them when they are all replaced. You can get away with less studs, but some or most will break and/or will have damaged threads after removing.
Parts/Tools List, (from your favorite automotive place):
These tools assume dropping off the entire turbocharger assembly at a re-builder.
| Description |
| Small anti-seize compound, (2,000 degree F copper or nickel based) |
| 90 degree Phillips driver, (for EGR heat shield) |
| 1/2" drive Metric Deep socket set |
| 1/2" and 3/8" drive Metric Standard depth socket set |
| 10mm box end wrench, (mostly for heat shields) |
| 14mm box end wrench, (for some of the pre-cat nuts) |
| 1/2" and 3/8" drive torque wrench |
| Stud removal tool |
Parts/Tools List, (from your favorite automotive place):
These tools are required in addition to the above when you remove Turbocharger Catriges from Turbo Assembly.
| Description |
| Big snap-ring tool, (for ~4" dia) |
Turbo Removal from engine:
Note, this is as I wrote down when doing this and remember, so use only as a guide
Sequence |
Step Description |
|---|---|
1 |
Remove small bottom heat shield, (when removing the nuts/bolts of the heat shield use lots of pentrating oil and allow to soak) |
| 2 | Remove vertical heat shield |
| 3 | Remove big bottom heat shield |
| 4 | Remove vertical heat shield |
| 5 | Remove heat shield for upper part of Pre-Cat manifold |
| 6 | Remove Primary and Secondary Compressor outlet as a unit, (if this has been pulled apart get a new O-ring N3A1-13-162) |
| 7 | Unplug O2 sensor, remove if you want to, else be VERY careful when removing Pre-Cat/Downpipe to not hit the O2 sensor |
| 8 | Remove Pre-Cat or Down-Pipe |
| 9 | Remove metal Secondary Compressor inlet |
| 10 | Remove Charge Relief Valve and Hose to Secondary Compressor outlet |
| 11 | Remove mini heat-shield for EGR Actuator on underside of Intake Manifold |
| 12 | Remove black plastic Primary intake elbow |
| 13 | Remove Water Cooling Lines and Oil Supply Line, (you can drain the coolant or be ready to plug the water lines asap). |
| 14 | Torque Turbo Assembly to Exhaust Manifold, start from center and work way to outside for torque pattern |
| 15 | Remove wastegate and turbo pre-control actuator C-clips on rod ends, |
| 16 | Remove tubes to/from Wastegate and Turbo pre-control Actuators, note any Restrictor Pills in the lines between Primary Compressor Housing and the Actuators. |
| 17 | Remove wastegate and turbo pre-control actuators from turbo assembly |
| 18 | Remove front/primary Oil Drain Line to Engine and Turbo Assembly and remove engine end of rear/secondary Oil Drain Line. |
| 19 | Remove, all nuts and bolts to hold Turbo Assembly to Exhaust Manifold, pentrating oil may be required here also. |
| 20 | Slide turbo off remaining studs, the Turbo Assembly weighs quite a bit and be carelfull of remaining oil drain line |
| 21 | Move Turbo Assembly to rear of car to remove secondary turbo oil drain gasket and line |
| 22 | Slide out Turbo Assembly through the top of engine compartment |
| 23 | Remove Exhaust gaskets |
| 24 | Remove any remaining 10mm and 8mm studs from Exhaust Manifold, (if you are going to replace them) |
| 25 | Remove Main heat-shield from Turbo Assembly |
Turbo Re-assembly to engine:
Note, this is as I wrote down when doing this and remember, so use only as a guide
Sequence |
Step Description |
|---|---|
| 0 | Make sure the surfaces of the turbo assembly that seal against the main manifold are in plane. This is set by clocking the housings relative to each other so they are in plane. |
1 |
Main heat-shield to turbo-assembly with small 10mm bolts, use anti-seize compound, (bolt specs are M6 x 16 if you want new ones) |
| 2 | 10mm and 8mm studs into exhaust manifold, use anti-seize compound on the end that goes into the casting, (see stud and bolt location diagram). |
| 3 | Exhaust gaskets on studs |
| 4 | Slide in Turbo Assembly, (without actuators) do not mount on studs |
| 5 | Move Turbo Assembly to rear of car to attach secondary turbo oil drain gasket and line |
| 6 | Place Turbo Assembly on studs |
| 7 | Attach, (but do not tighten) all nuts and bolts to hold turbo to exhaust manifold |
| 8 | Check that both oil drain lines line up with engine |
| 9 | Check that Secondary Turbo Compressor Inlet lines up, (temporarily place metal Secondary Compressor Inlet pipe and see how it lines up with the top attachment stud/grommet on Intake Manifold). |
| 10 | Attach both Oil Drain Lines to Engine and Turbo Assembly |
| 11 | Attach wastegate and turbo pre-control actuators, put rod on turbo valve arm, then pull actuator and attach with bolts. Attach tubes c/w restrictor pills and attach C-clips on rod ends |
| 12 | Torque Turbo Assembly to Exhaust Manifold, start from center and work way to outside for torque pattern |
| 13 | Attach water cooling lines and oil supply line |
| 14 | Attach black plastic Primary intake elbow |
| 15 | Attach mini heat-shield for EGR actuator on underside of Intake Manifold |
16 |
Attach Primary and Secondary Compressor outlet, (if this has been pulled apart get a new O-ring N3A1-13-162) |
| 17 | Attach Charge Relief Valve and Hose to Secondary Compressor outlet |
| 18 | Attach metal Secondary Compressor inlet |
| 19 | Attach Pre-Cat or Down-Pipe |
| 20 | Attach heat shield for upper part of Pre-Cat manifold |
| 21 | Attach vertical heat shield, (do not tighten) |
| 22 | Attach big bottom heat shield |
| 23 | Tighten vertical heat shield |
| 24 | Attach small bottom heat shield |