I had just fitted my new intercooler and started the car up to make sure the fan was wired the right way and the turbo spunked a little condensation out of where the wastegate housing bolts onto the turbo...

Went to tighten it up and one stud sheared straight off
Half an hour later i had the turbo and exhaust manifold on the workbench to find that out of five studs, one had sheared underneath that i didnt know about, another had sheared (That i just did myself) and the remaining three were loose
I tried to remove the other three studs and two of them sheared. Fook.

So anyway, i started drilling them out and retapping the holes, and they were all going fine until i drilled right through into the exhaust snail on one of the holes All the others had a gap behind the stud i.e. when you drilled through the stud, there was a small gap at the bottom of the stud hole (between the end of the stud and the bottom of the threaded hole(. This last one just went straight through.

Question is, if any swarf has gone inside the turbo exhaust housing, do i absolutely have to get it out, or will it just blow through when i start the engine?
Is it easy enough to take the exhaust snail off?

Anyone?


Please?