Resolved Evo 3, 2g exhaust manifold install on 1g

[arbowman]

Hey whats up everyone? This is my first post and I'm sure it won't be my last!

I am installing a new turbo setup on my 1g. I have a ported Evo manny, ported small 16g with 34mm flapper, and a ported 2g 02 housing all gasket matched really close. I did all the porting myself too. Took awhile to finish but I think I did a good job. Maybe I'll post some pics when I get the final polishing done so I can get some opinions on how it looks but anyway here is my question.

Apparently before I install any of this stuff, I need to trim off one corner of the Evo manifold to clear the power steering bracket. This was according to RRE. Here is the quote from their site regarding the Evo manny: "They are a direct bolt on for a 2G, they require the same slight trimming on one corner when used on a 1G to clear the P/S bracket as a 2G manifold would need." So, I compared that corner of my new manny to the old one and I'm just not seeing what needs to be trimmed. The flanges look the same to me and I didn't feel the new manny hit the bracket when I test fit it.

Can somebody post a pic or make a diagram or just give a detailed description of what exactly I need to be trimming off? I don't wanna hack my new manifold up any more than I have to and I am also not 100% sure it is clearing the bracket when I test fitted it.

Thanks in advance.

 

[dsm-onster]

I didn't need to grind anything either. So I was confused by that quote, too. Just try to bolt it on and see what happens. . .

 

[Cs4g63]

I also havent had to grind anything for a 2g manifold to fit on either of my 1g's. WTF

 

[dikdiamond]

Would the same apply for an automatic? Plan to do the same setup

 

[arbowman]

My TSi is an auto as well and I don't think there is any difference. To the best of my knowledge and please correct me if I am wrong, the only differnce between an auto trans turbo setup and manual trans turbo setup is a different oil supply line. The water and oil drain lines look the same. The banjo bolt for the oil feed line is smaller for the 13b/g (not sure which one it is) and the oil line is sized accordingly for the smaller bolt. I've compared my old setup and new setup and that is the only difference I can see. Hopefully, I not forgetting or missing anything else because I am installing everything tomorrow. Wish me luck!

 

[Auto RS T]

The bracket in question is the bracket behind the power steering pump that bolts down to the engine block behind the water pipe. If the manifold clears that bracket and sits flush to the head, then your fine.

If the manifold doesn't clear the bracket, you will need to either grind the Power Steering bracket down or the edge of the manifold where it is contacting the PS bracket. Personally, I would try grinding the bracket with a dremel or a tool of that nature.

Quick tip: Do not over tighten the turbo oil drain to oil pan bolts, they are commonly stripped out.

Quick parts list:

• head to manifold gasket
• manifold to turbo gasket
• O2 housing to turbo gasket
• O2 to down pipe gasket
• turbo oil and coolant lines
• oil drain line gaskets
• new crush/banjo washers
• turbo outlet elbow gasket (possibly an upgraded elbow at this time)
• New manifold to turbo bolts from the dealer (4) (replace the stud with a bolt)
• I also suggest new manifold to head nuts

 

[dikdiamond]

Good luck! Keep us updated,I am planning on doing this set-up either in the fall or spring,and want to know what(if any)cutting/grinding is required. Since the oil lines are smaller on the 13 B(?G) are the coolant lines small as well? I want to get a 16g or the Evo 3 turbo

 

[kenamond]

This is the vfaq article talking about grinding down the end of the mani:

http://www.vfaq.com/mods/porting-exhman.html