best way of changing downpipe?
 

Just ordered a tsl motorsport group a decat downpipe which I will have on saturday. What is the best way of fitting it, are there any special procedures or anything like that, you know removing intercooler and such like.
(please no one say remove the old one first!!!)

Its a classic MY92

Pay Scoobyclinic ~£60 to do it..!;)

not really an option as getting a power fc fitted and mapped next month so need to save pennies!

Remove intercooler.. 3x12mm bolts, then the jubilees on throttle body and turbo.. pull towards passenger side with a wriggle.. not you the intercooler lol.. to get off turbo.. careful if you lever the pipe as it is sometimes brittle.

need a 14mm preferably ratchet spanner and same in 10mm, and same size sockets.
Remove the heat shield over the turbo.. from memory.. 10mm bolts - 5 if I remember correctly. Two on passenger side, one on the rear and then two right down the bottom on drivers side..might be others only removed mine the once before it was cut for downpipe.. some might sheer if they have never been removed.

Then you have the 14mm ones to remove.. two bolts in the top (need second 14mm spanner etc) then nuts to come off studs... outside edge ones you can get to with spanner from top, but I find the middle one is easier with socket and extension from underneath.. jack and axle stands need to get under.

The key is a good quality spanner, Halfords professional are actually very good.

You then just have the two bolts to the centre section and one support bracket where the downpipe runs back under the car and the bracket is attached to the gearbox.

iirc you said your cat on fire sensor is already disconnected so no hassle there and no lambda to refit in downpipe.. fit bung before you fit downpipe for convenience.

I attach downpipe to turbo first to make sure it is done up flush and then do the support bracket which mine not longer lines up for.. probably when I dropped the gearbox when I had that out lol.. then attached to centre section obviously.

To get the intercooler on easier heat the turbo end of the pipe with hot water.. dip it in a mug full of boiling water.. it should then slide on without too much effort if you are quick.. this is assuming you still have the black plastic pipe.. if changed to samco then it should just push on.. put the jubilee further up the intercooler pipe and tighten it slightly before hand then you can undo it and move it down once on the turbo.. then do the throttle body connection..

You will need to cut the heat shield as the new downpipe will be fatter..

You might want to get a new gasket to save doing it again when it leaks.. although mine has been on and off a few times on the same gasket.

Tired so sorry if I waffled or made little sense :)
Simon

Simon, do you write Haynes manuals by any chance????? lol

Cheers Simon, once again to the rescue!!!

I think it needs some pictures.. lol

I was thinking when I typed that, "I should save this and then I can just cut and paste and save my now aching fingers for next time!" lol

Hope it is kind to you.. they rarely are though.. you can tell cars are female ;)

Simon

Cheers for that snippet of info, hands are just about recovered from doing laminate flooring last weekend!!

Whilst your on, just got my knocklink this morning where is the best place to fit the sensor?

oh by the way the TSL downpipe starts at 3 inch and tapers down to 2.5 same as standard

lol..

when you take the intercooler off.. look where the starter motor is on the rear of the engine passenger side / front of gearbox and follow it up towards the inlet manifold / throttle body and there is a convenient threaded hole.. it is not far from the original sensor whcih is slightly further forward.. just had a look and I don't unfortunatly have a picture.. I know Tim has.. calling Tim for knock sensor location picture! ;)

Simon

dont suppose you know what size bolt would be needed for the threaded hole do you?

I used the bolt from my intercooler.. although it was a little on the long size.

Simon

hope the weathers kind to me tomorrow......

Well used your instructions Simon, worked a treat, took me about 2.5 hours (with tea breaks and waiting whilst penetrating spray worked its magic on the bolts/nuts on the turbo end)
Quite an easy job actually, was surprised how much room there is to work in a subaru engine bay when the intercooler is removed, only got 2 cuts on my hands as well, maybe a record!
Managed to fit the knock link as well just need to tidy the wiring up in the car now.

meant to say, it now sounds even sound more meaty now, not been for a test drive as gf parked her car behing mine on the drive and went out with her keys - (daft cow), so just reved it on the drive (probably to the annoyance of the neighbours)

been out today in her, feels more responsive (will have to adjust the duty on the boost controller), and the sound is just awesome, it was good before but now on full chat, well.........

Excellent glad it went on easily Jay!

Simon

Well only had 2 cuts, however woke up this morning and I have loads of bruises on both arms. Ahh well, no pain no gain!!!

oops!