2g exhaust mani on a 1g need help

[wcpierson]

i know i need to grind down the one corner make it fit on my 1g but is there any illustration of how much i actually have to take off and which corner it is.....also need to know how difficult it is to swap them out and how long u think it should take me...thanks

 

[DSMcamaro]

http://www.dsmtuners.com/forums/showthread.php?p=150997426#post150997426
the amount of time will depend on your skills and how many bolts break I spent about 2 hours just trying to remove a broken stud from my head and eventually drilling, taping and helicoiling it.
vfaq is your friend.
http://www.vfaq.com/index-main.html
http://www.vfaq.com/mods/porting-exhman.html

 

[boosted-dsm]

i thought i saw a thread like this before..

 

[kenamond]

The vfaq link will show you which corner, but I think you'll have to grind/testfit/grind/testfit until you get the clearance you need.

As far as time, soak the crap out of everything with PB blaster (go buy a can from your local auto parts store if you don't have a can, as you're gonna be using it a LOT on your DSM). That will help with breaking bolts.

Keep in mind that the head is aluminum and the studs are steel.

If all goes well, it could be done in a few hours, but anything more exact is gonna depend on you.

If you haven't torn the car down, make sure you've got all of the parts you're gonna need/want. I'm a 2g guy, so I'll speak from that perspective.

I'd recommend getting a new stud/nut set for the head/mani, head/mani gasket, mani/turbo gasket, and mani/turbo bolts (get rid of the mani/turbo stud if you still have it).

If you're dropping the turbo, you may want to replace the O2/DP gasket.

If you're separating the turbo/O2 housing, get a new turbo/O2 gasket.

If you could benefit from porting, now's a good time .

Get anti-seize for the mani/turbo bolts and turbo/O2 bolts (if you're pulling them apart).

Make sure you know the torque specs for everything, especially the head/mani nuts (aluminum is pretty soft compared to steel).

If you lack a breaker bar for those turbo/mani bolts, a bicycle seat post works great! Just slip it over your ratchet handle. Don't forget the PB Blaster, and don't forget to let it sit for an hour or more. Patience, after all, is a virtue .