I got some work done this past weekend and I'll post the pics a soon as I get them annotated.
I also had some surprises and my parts list is growing.
Also whom ever the previous owners mechanic was did not put the clamps back on the turbo intake hoses; one was there but not clamped on the hose and the other was missing. The heat shield was not on correctly and the clamp there cut through it; also the mount bolt for the big flat metal tube was missing and it was hanging freely [CCH DIY 044].
So when I took these items off, engine oil drained
from the intercooler; this is my first turbo, but I do think
that this is normal. So I poked my finger in the intercooler intake tube and there is a substantial pool of oil in it!
[CCH DIY 047]
Also the turbo itself is coated in oil, as it looks wet and shiny; so I'm thinking it might have a bad head gasket as well.
So another surprise was that the oil pan took a hit and big one as it has been sealed buy something that looks like brown tinted glass; so I'll need a new oil pan [CCH DIY OIL PAN].
Yet another surprise was the coolant pipe that follows the frame on the passenger side and loops around to the back was rusting so badly where the plastic clamps hold it to the frame that the clamps are misshapen. Also this pipe connects to the auxiliary water pump at the bottom of the radiator and it has pink crusty residue all around it, so all of that will need to be replaced [CCH DIY RUSTY TUBE] & [CCH DIY 044-A & 044-B].
Step Fifteen: [CCH DIY 039, 041, 042 & 043] Remove Turbo Air Intake tube; disconnect sensor #1 and vacuum tubes #2 and #3. Take care as the vacuum connector is plastic and the intake tube is rubber, so getting it off without breaking something is a challenge. Getting the turbo retaining clip 043-1 off is definitely challenging; be careful not to lose the retaining clip. You will also need to disconnect hose 013-10 and 048-1 and with a little twist the turbo intake tube will come out.
Step Sixteen: [CCH DIY 044, 045 and 047] Remove the Lower Intercooler Pipe, which goes from the turbo (049-2) to the intercooler (047-1) and consists of two metal pipes (upper & lower) with rubber tube connectors. #044-1 is the upper clamp protruding from the heat shield. The heat shield has two snaps that you unsnap so you can slide it down to get to the upper clamp. #3 Is the lower clamp, which mine did not have, nor did it have the bolt #4 which secures the metal tube to the frame, nor did it have the #047-2 for the intercooler connection. So I simply remove intercooler clamp #047-1 and remove the tubing in its entirety. I then slid the heat shield off of the upper tube and removed the #1 clamp. Be gentle with the heat shield or you will rip the seam #045-2, like I did; another part to add to the list!
Step Seventeen: [CCH DIY 046, 049 and 050] Remove the Upper Intercooler Pipe, which connects to the lower intercooler pipe on the backside of the cylinder head. The upper intercooler pipe has a heat shield (no picture); this heat shield has several snaps to unsnap and it will come off; take great care or like the lower heat shield you will rip the seam. Then unbolt the two clamp bolts #046-1, #049-1 and the turbo clamp #049-2 and the upper intercooler pipe will come out.