Fitting a down pipe
Scooby Regular
Joined: Mar 2008
Posts: 691
Likes: 0
From: chelmsford essex
Get 1 of your mates to help you for 1 bit.
Remove the intercooler 6 bolts. 4 at front then the 2 on top. Unscrew the two jubilee clips on the turbo outlet and 1 on the intercooler. Remove the 2 bolt of the dump valve then remove the intercooler. Gives you more space, you don't have to do this but I recommend it. And takes 5 minutes.
Next spray wd40 on all the bolt's on the turbo heatsheild. There are 7. Leave it to soak for 20 minutes. Take of all the bolts. Racket spanner is best.
Wiggle and remove the heatsheild it will come off.
Remove the heatsheild mounting bracket 1 bolt.
Spray wd40 all five bolts on the downpipe to turbo.
Leave for 20 minutes.
Undo the five bolts on d/p to turbo. 4 are easy but 1 is hard to get to but be patient. They will come off.
Undo the bolt from d/p to gearbox. Half way down the d/p.
Jack the car up and put on axle stands or ramps if you have them.
Spray the 2 bolts d/p to centre section.
Undo the 2 bolts from the btm of the d/p to the centre section. (While your mate is holding it or it will fall on your head).
Remove the d/p. (your mate does this from above the car).
Jack the car down.
Put in the new d/p 5 bolts onto turbo tight as you can with new gaskets. (I recommend you do but you don't have to).
Jack up the car.
Put in the 2 remaining bolts from d/p to centre section. (You need your mates help here to move the pipes)
Assemble the intercooler bracket, then heatsheild (this will need butchering before replacement because of the new d/p).
Assemble the intercooler job done.
Remove the intercooler 6 bolts. 4 at front then the 2 on top. Unscrew the two jubilee clips on the turbo outlet and 1 on the intercooler. Remove the 2 bolt of the dump valve then remove the intercooler. Gives you more space, you don't have to do this but I recommend it. And takes 5 minutes.
Next spray wd40 on all the bolt's on the turbo heatsheild. There are 7. Leave it to soak for 20 minutes. Take of all the bolts. Racket spanner is best.
Wiggle and remove the heatsheild it will come off.
Remove the heatsheild mounting bracket 1 bolt.
Spray wd40 all five bolts on the downpipe to turbo.
Leave for 20 minutes.
Undo the five bolts on d/p to turbo. 4 are easy but 1 is hard to get to but be patient. They will come off.
Undo the bolt from d/p to gearbox. Half way down the d/p.
Jack the car up and put on axle stands or ramps if you have them.
Spray the 2 bolts d/p to centre section.
Undo the 2 bolts from the btm of the d/p to the centre section. (While your mate is holding it or it will fall on your head).
Remove the d/p. (your mate does this from above the car).
Jack the car down.
Put in the new d/p 5 bolts onto turbo tight as you can with new gaskets. (I recommend you do but you don't have to).
Jack up the car.
Put in the 2 remaining bolts from d/p to centre section. (You need your mates help here to move the pipes)
Assemble the intercooler bracket, then heatsheild (this will need butchering before replacement because of the new d/p).
Assemble the intercooler job done.
Last edited by escott; Aug 13, 2008 at 11:04 PM.
Some great advice mentioned above.
I found a 10 mm ratchet ring spanner essential for the turbo heat shield (some bolts may snap off) and a good 14mm ring and socket spanner for the bolts holding the down pipe to the turbo.
Oh and a few plasters for the knuckles
.
I found a 10 mm ratchet ring spanner essential for the turbo heat shield (some bolts may snap off) and a good 14mm ring and socket spanner for the bolts holding the down pipe to the turbo.
Oh and a few plasters for the knuckles
.
Get 1 of your mates to help you for 1 bit.
Remove the intercooler 6 bolts. 4 at front then the 2 on top. Unscrew the two jubilee clips on the turbo outlet and 1 on the intercooler. Remove the 2 bolt of the dump valve then remove the intercooler. Gives you more space, you don't have to do this but I recommend it. And takes 5 minutes.
Next spray wd40 on all the bolt's on the turbo heatsheild. There are 7. Leave it to soak for 20 minutes. Take of all the bolts. Racket spanner is best.
Wiggle and remove the heatsheild it will come off.
Remove the heatsheild mounting bracket 1 bolt.
Spray wd40 all five bolts on the downpipe to turbo.
Leave for 20 minutes.
Undo the five bolts on d/p to turbo. 4 are easy but 1 is hard to get to but be patient. They will come off.
Undo the bolt from d/p to gearbox. Half way down the d/p.
Jack the car up and put on axle stands or ramps if you have them.
Spray the 2 bolts d/p to centre section.
Undo the 2 bolts from the btm of the d/p to the centre section. (While your mate is holding it or it will fall on your head).
Remove the d/p. (your mate does this from above the car).
Jack the car down.
Put in the new d/p 5 bolts onto turbo tight as you can with new gaskets. (I recommend you do but you don't have to).
Jack up the car.
Put in the 2 remaining bolts from d/p to centre section. (You need your mates help here to move the pipes)
Assemble the intercooler bracket, then heatsheild (this will need butchering before replacement because of the new d/p).
Assemble the intercooler job done.
Remove the intercooler 6 bolts. 4 at front then the 2 on top. Unscrew the two jubilee clips on the turbo outlet and 1 on the intercooler. Remove the 2 bolt of the dump valve then remove the intercooler. Gives you more space, you don't have to do this but I recommend it. And takes 5 minutes.
Next spray wd40 on all the bolt's on the turbo heatsheild. There are 7. Leave it to soak for 20 minutes. Take of all the bolts. Racket spanner is best.
Wiggle and remove the heatsheild it will come off.
Remove the heatsheild mounting bracket 1 bolt.
Spray wd40 all five bolts on the downpipe to turbo.
Leave for 20 minutes.
Undo the five bolts on d/p to turbo. 4 are easy but 1 is hard to get to but be patient. They will come off.
Undo the bolt from d/p to gearbox. Half way down the d/p.
Jack the car up and put on axle stands or ramps if you have them.
Spray the 2 bolts d/p to centre section.
Undo the 2 bolts from the btm of the d/p to the centre section. (While your mate is holding it or it will fall on your head).
Remove the d/p. (your mate does this from above the car).
Jack the car down.
Put in the new d/p 5 bolts onto turbo tight as you can with new gaskets. (I recommend you do but you don't have to).
Jack up the car.
Put in the 2 remaining bolts from d/p to centre section. (You need your mates help here to move the pipes)
Assemble the intercooler bracket, then heatsheild (this will need butchering before replacement because of the new d/p).
Assemble the intercooler job done.
I need to change mine over soon for a 3 inch item, great write up.
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