Exhaust manifold and O2 dump install in 2 hours.

[MyEclipse5]

Well I have an auto-tech class, and we have two hours in the class. I am going to bring in my car to finish up the installs I started two weeks ago. First of all, all of the bolts are loose, because i undid almost everything last time. But time ran up, so I had to put it all back together without getting on my new parts. My first question is: How do i get the turbo to come down? I know I have to take out that stupid stud and replace it with a bolt, but I need to know what else is involved in dropping the turbo.

here is this pic:

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So tell me what all i need to remove.

Here is what I am going to do:

Remove the power steering pump.
Remove radiator fan
Remove all bolts that connect exhaust manifold to block.
Remove bolts that connect Exhaust manifold to Turbo.
Remove the stud(hope this doesn't take TOO long)
Remove the bolts that connect the O2 to the Turbo
Remove nuts that connect O2 to DP
Do what I have to do(please tell me) to drop the turbo (or atleast move so I can put the dump on, and so that I can take out the "ring thing")
Remove Exhaust manifold
Remove O2
Put new exhaust manifold gasket and manifold on the studs
Put new gasket and O2 dump on the turbo
Anti sieze the bolts that go from Exhman to turbo, and tighten
anti sieze studs and put the nuts back on
anti sieze studs on turbo, and screw on the nuts that connectit to the O2
Bolt the O2 to the DP (i have to do this because my new one has no threads for studs)
Put power steering back together
put fan back on
tighten it all down to spec
Drive off happy.

I will have all wrench's and sockets handy. 12mm/13mm/8mm(for fan, i think thats the size)/19mm(for DP)/23-25mm(for O2 sensor..he doesn't have a deep enough O2 socket)

If i don't get this done, ill ave to wait another 2 weeks...my car has so many exhaust leaks because i dind't tighten them down to spec last time. My car sounds like crap, and i know its bad on the car..if i boost over 5lbs i loose all my boost because it leaks out..its that bad. Think i can power through it Friday?

 

[Spln_Hrd]

well if you are removing the turbo in this job because you said what do you have to do to get the turbo out

you need drain the antifreeze and pull the turbo antifreeze feed and return houses. you need to remove the turbo oil feed and return lines


a tip for getting the stud: use a nut from your exhaust manifold(one of the smaller nuts(2 on the outside are larger)) put the nut for the stud on the stud and the nut from your manifold on the stud and tighting the top one and loosin the bottem so that they squeeze into eachother and then use a wrench on the bottem one to loosin the stud out

 

[CanadianTSi]

Just pull the Manifold out so it's off the studs, then pull it up and off the 1 stud in the turbo.

 

[MyEclipse5]

I dont' really want to remove the turbo, just more it around alittle bit.

 

[David15151]

yeah you dont need to pull the turbo to get the 02 housing or the manifold off. Just unbolt the bolts holding it to the manifold and that gives it enough play to pull the 02 housing. Take the bolts off from the manifold to head and pull up.. bam its off. Reverse steps for install. Not that hard really. Just be very carful with the bolts. I snaped one of the studs and stripped a few nuts on the manifold. Plus i ended up snaping off a bolt from the 02 and cross threading it yay! .. but if i didnt do all that fun stuff i wouldnt have learned how to do it right way.

only thing i really removed was the driver side fan to get more room.

 

[MyEclipse5]

yeah you dont need to pull the turbo to get the 02 housing or the manifold off. Just unbolt the bolts holding it to the manifold and that gives it enough play to pull the 02 housing. Take the bolts off from the manifold to head and pull up.. bam its off. Reverse steps for install. Not that hard really. Just be very carful with the bolts. I snaped one of the studs and stripped a few nuts on the manifold. Plus i ended up snaping off a bolt from the 02 and cross threading it yay! .. but if i didnt do all that fun stuff i wouldnt have learned how to do it right way.

only thing i really removed was the driver side fan to get more room.

O could take off my O2 but its hard because of the dipstick. Also the Exhman wouldn't come off when I unbolted everything. But the stud was still in, so is that the reason why it wouldn't come out?

 

[David15151]

i dunno if the 2g and 1g set up are a little different or not but i was able to move the turbo around enough with it loose from the manifold to get all the bolts of the 02 housing. try disconnecting the 02 from the down pipe first so it can move freely.

You mean you still have the stud on the turbine housing? yeah take that crap out and replace with a bolt 10x80 1.25 is the size.

and if you need new bolts for the 02 housing they are 10x30 1.25

 

[MyEclipse5]

Yea, i think the 1g's are a little different. I had everything but the stud out, (but i think that may have been the biggest problem) Friday i ddo the install.


My next question is this: How much extra time will it be to drain my coolant so that i can take off that "return line" (I'g guessing its the line at the bottom) And do i HAVE to drain it? Can i just undo it and let the coolant run out, then top it off later? or no? I'm trying ot make this as short as possible, considering i only have about 2 hours, maybe a little bit more.

 

[damentor]

Yea, i think the 1g's are a little different. I had everything but the stud out, (but i think that may have been the biggest problem) Friday i ddo the install.


My next question is this: How much extra time will it be to drain my coolant so that i can take off that "return line" (I'g guessing its the line at the bottom) And do i HAVE to drain it? Can i just undo it and let the coolant run out, then top it off later? or no? I'm trying ot make this as short as possible, considering i only have about 2 hours, maybe a little bit more.

I didn't drain it all when I took mine part. I let it out till it stopped dripping from the turbo then filled it back up later. That doesn't take much time at all. Your list of what you're going to do seems far more time consuming and out of your way than what is probably needed in order to get that job done. That's just my 2cents worth anyway.

 

[MyEclipse5]

I didn't drain it all when I took mine part. I let it out till it stopped dripping from the turbo then filled it back up later. That doesn't take much time at all. Your list of what you're going to do seems far more time consuming and out of your way than what is probably needed in order to get that job done. That's just my 2cents worth anyway.

Well then what should I do? Make a list for me . I'm pretty sure i have to do all of that stuff.

 

[FourG63GST]

you dont have to take your turbo out or your power steering pump out

Un bolt the bolts holding manfold to head. unbolt the bolts from mani to turbo. use vice grips to pull studs out. take off your stock o2. wiggle around the mani till it comes off. this will take patience becuase the ring is annoying. you dont HAVE to put the ring or the stud back in.

 

[MyEclipse5]

you dont have to take your turbo out or your power steering pump out

Un bolt the bolts holding manfold to head. unbolt the bolts from mani to turbo. use vice grips to pull studs out. take off your stock o2. wiggle around the mani till it comes off. this will take patience becuase the ring is annoying. you dont HAVE to put the ring or the stud back in.

Yes, i have the take the bracket for the power steering pump off, otherwise i can't get to the last bolt.

 

[David15151]

just use a deep socket

 

[saw wave analog]

dont use vice grips on the stud if you ever plan on using it again, the best way to get it out as was mentioned is to put 2 nuts on it, tighten them together as much as you can, then back out the one on the bottom.. though the turbo has enough movement that i dont know if you even need to take the stud out, the dipstick can be removed, there is only one bolt holding it in.. disconnect the dp from the o2 housing and once you have the manifold to turbo bolts out the whole assembly should wiggle enough to be able to slide the manifold off the head and then up off the stud.

takes me 20 minutes to get either one off, but then ive done it a few times before.

be careful that you dont break any of the lines that go into the turbo when you move it.. i have a stainless oil feed line on so maybe i get more flex than i would with the stock hard one. if it feels like you are straining anything bite the bullet and disconnect whatever it is.. better than breaking it and then having to disconnect it anyway with the added bonus of more downtime.

 

[MyEclipse5]

dont use vice grips on the stud if you ever plan on using it again, the best way to get it out as was mentioned is to put 2 nuts on it, tighten them together as much as you can, then back out the one on the bottom.. though the turbo has enough movement that i dont know if you even need to take the stud out, the dipstick can be removed, there is only one bolt holding it in.. disconnect the dp from the o2 housing and once you have the manifold to turbo bolts out the whole assembly should wiggle enough to be able to slide the manifold off the head and then up off the stud.

takes me 20 minutes to get either one off, but then ive done it a few times before.

be careful that you dont break any of the lines that go into the turbo when you move it.. i have a stainless oil feed line on so maybe i get more flex than i would with the stock hard one. if it feels like you are straining anything bite the bullet and disconnect whatever it is.. better than breaking it and then having to disconnect it anyway with the added bonus of more downtime.

IF the Stud is out, it shoudl be enough to wiggle free? Because i had everything but the stud out last time, and it was budging. I'm going to try the nut thing first, but i already bought another bolt to put in that spot.

 

[joeracer321]

I don't know if I would attempt that under time constraints, that is the perfect opportunity for murphys law. I would get the basic tools you need and do it at home. Tools are always a wise investment. Good luck

 

[MyEclipse5]

I don't know if I would attempt that under time constraints, that is the perfect opportunity for murphys law. I would get the basic tools you need and do it at home. Tools are always a wise investment. Good luck

Hmmm, work in a Heated garage, or work in my garage where it would be under 30 degrees....what would you do?

Winter sucks,.

 

[Tallen]

Wow this is awesome.

Take off heatshield if it isnt.
Remove all of the 12mm exh mani nuts except the bottom right one.
Remove engine lift bracket
Use a 12mm universal swiveling socket and a long extension to remove the nut thats deep down there.
Remove the 3 bolts and one nut from the manifold.
At this point just wiggle it free, the manifold and turbo may be stuck together via the gasket. If theres not enough room for movement, remove the downpipe brace.

As for the O2...you know that the dipstick and dipstick tube just pop out, correct? Just unbolt and rebolt.

Do them one at a time incase you hit a snag.

 

[90CherryTSI]

Here's what you do -

Remove driver side fan
Remove exh mani heat shield
Loosen the o2 housing to DP nuts
Remove all bolts holding exh mani to the head
Remove the bolts holding the exh mani to the turbo
Remove the bolts holding the o2 to the turbo
Wiggle the exh mani free
Wiggle o2 free (I had to pull down a little on my DP to do this part)

Swap the stuff, and put it back together in reverse order

Don't pull the pump, dont drain the fluid, no need to touch any of that

Good luck!

 

[InferiorWang]

Hmmm, work in a Heated garage, or work in my garage where it would be under 30 degrees....what would you do?

Winter sucks,.

two words. space heater.

 

[MyEclipse5]

Post a pic of you fitting whatever you have into the space between the Power steering bracket and the last nut on the right side, and then ill belive ya.

Did the install today, stayinh after for 1/2 an hour but i got to miss a class .

got my O2 dump in, but the exhaust manifold is a no fitter..i dunno if you have to work it on or what, but im selling it..im not going to even bother.

So if anyone wants a ported 2G Exhaust mani let me know .

It was a good day..my dump sounds "mad tyte"