Well I'm going to be doing my exhaust manifold gasket, manifold-turbo gasket, and turbo-cat gasket.
Do you need to use any gasket maker compound for any of these gaskets?

 

theres nothing that will really stand up to the heat, so no. the two turbo gaskets are fairly soft (in comparison to the all metal manifold gasket) and form to the flanges. so basically, just no, dont put anything on there

 

I would recommend you pick up a cat/test pipe installation kit from RAI or 034. They have very nice gaskets and copper lock nuts with washers that are WAY easier to deal with than the OEM hardware.

 

CCA4 brings up a good point: anywhere there are nuts, you'll need to replace them as they are one-time use. This means you should replace the following:

-exhaust manifold nuts (12-13 of them)
-exhaust manifold studs, if you can get them out (12-13 of them) (I've never replaced these on my car since I couldn't remove them)
-turbo bolts (3 of them) (you can re-use the washers)
-turbo-to-cat studs (3 of them)
-turbo-to-cat nuts (3 of them)

Are you planning to remove the turbo from the car when you do this work? You almost need to pull it when taking off the exhaust manifold. And if you do, you'll need to disconnect the oil/coolant lines. If you disconnect the oil coolant lines, you need new copper sealing washers for the oil and coolant lines, and gaskets for the oil return line.

 

I was able to do it without removing the turbo or the oil lines. But I did end up snapping a stud for the manifold. How are these studs even removed in the first place?

I'd rather do my timing belt again instead of replacing all these gaskets, such a PITA when you have limited space. I did use PB Blaster overnight, amazing how well it worked.

 

i had a broken stud, but i brought the head into the machine shop so i just had them get it out. oftherwise, they do make stud extracors. is there any bit of stud sticking out? you could try a vise grips and heat

 

It snapped flush the the manifold when I was installing it back on. I don't hear a leak nor smell anything as of now.
Can you link me to a stud extractor?

Also what could cause the stock turbo to flutter when you let off the gas after high revving, a bad DV?

 

dont know how much youre willing to spend but you need something like this
Mac Tools Online Store - 10-PC. Left Hand Combination Extractor and Cobalt Drill Set

 

What you can do to extract the broken stud is take a rotary tool and cut a slot it in and use a big flathead screwdriver to help it out.

Doug

 

I think I have a set in the garage. I'll have to look up how to use them . But nothing is leaking as of now. So should I fix what isn't broke?

As for cutting a slot for a big flat head, wouldn't I require a ridiculous amount of torque to free the stud?