Exhaust manifold/O2 Dump install...

[MyEclipse5]

Friday I am installing my O2 Dump, and 2G (ported) Exhaust manifold. My First question is this: I alwayshear of people breaking "bolts" which bolts are these, and is there a way that i won't break them. I am doing this at school, i have 2 hours. I am not that experienced, but we have a kid who is going to help me who is already a mechanic(and knows his stuff). But still do i need to buy any bolts just in case? I don't want to have to take the school bus home and then come back later to get/fix my car. I already have all of the gaskets, and the school has the tools. So what shjould i do, and whatbolts should i buy just in case?

 

[Meh987]

Some people break or strip the 4 manifold to turbo bolts. I would suggest spraying them in advance with penetrating oil. It helps to do it a few days in advance, like once everyday. This should make them come out easier.

 

[MyEclipse5]

Thnx, any more advice?


Also how long should this take? I only have 2 hours in the class.

BTW

I would suggest spraying them in advance with penetrating oil. It helps to do it a few days in advance, like once everyday. This should make them come out easier.

Like WD-40?

 

[Meh987]

I used PB Blaster. Great stuff.

Also, if nothing goes wrong, you should be able to finish it in two hours, but usually things go wrong and it takes longer.

 

[MyEclipse5]

I used PB Blaster. Great stuff.

Also, if nothing goes wrong, you should be able to finish it in two hours, but usually things go wrong and it takes longer.

Could you, or someone, list some things that would go wrong. I have time to prepare, and talk to the teacher/kid in school.

 

[saw wave analog]

one of the bolts that holds your turbo onto the manifold isnt a bolt at all, rather it is a long threaded stud (basicly a bolt with no head) that can be a real bi*** to get off if it hasnt been taken out for a long time. pop off your upper heatshield and look at the 4 bolts, one of them will look different than the rest.. thats the stud. the preferred method for removing the bastard is to thread a nut onto it so it is tight against the manifold and there are still some of the studs threads sticking out the top of it, you then thread another nut onto it snug against the first, then get 2 wrenches and get those nuts as tight against one another as humanly possible by loosening the bottom one and tightening the top one at the same time, then put yer wrench on the bottom bolt and try to unscrew it.. hopefully it will start backing the stud out if the 2 bolts are locked toghether tight enough. this in and of itself took a good hour or so and quite a few attempts to accomplish it the first time i had my turbo off. its probably a good idea to break that sucker loose before you go into school on a time limit because if the stuff hasnt been removed in a long time you probably arent going to finish in 2 hours if you have never done anything like it before.


removing the manifold and o2 housing is a very easy job, the only pain in the ass is if the nuts and bolts are rusted. upper and lower headshields need to come off, the manifold bolts to the head with i think 9 bolts, and to the turbo with 4 bolts. the o2 housing bolts to the turbo with 3 bolts and another one of those giant pain in the ass studs, and to the downpipe with 2 bolts. make sure you have an o2 sensor socket to break the sensor loose, do that before loosening everything up because it is going to take some serious pulling to remove it at first. when you are putting everything back together coat EVERY threaded connection with high temp (2000 degree+ if you can find it) antisieze so next time it isnt such a pain. its also a good idea to get bolts to replace those studs since they are so incredibly annoying to work with.. your local mitsu dealer hopefully has a couple in stock to sell you.. um.. thats about all i can think of.. i just had my manifold off to port it last night and my buddy had his o2 housing off as well so all this stuff is pretty damn fresh in my mind

 

[MyEclipse5]

one of the bolts that holds your turbo onto the manifold isnt a bolt at all, rather it is a long threaded stud (basicly a bolt with no head) that can be a real bi*** to get off if it hasnt been taken out for a long time. pop off your upper heatshield and look at the 4 bolts, one of them will look different than the rest.. thats the stud. the preferred method for removing the bastard is to thread a nut onto it so it is tight against the manifold and there are still some of the studs threads sticking out the top of it, you then thread another nut onto it snug against the first, then get 2 wrenches and get those nuts as tight against one another as humanly possible, the put yer wrench on the bottom bolt and try to unscrew it. this in and of itself took a good hour to accomplish the first time i had my turbo off. its probably a good idea to break that sucker loose before you go into school on a time limit because if the stuff hasnt been removed in a long time you probably arent going to finish in 2 hours if you have never done anything like it before.


removing the manifold and o2 housing is a very easy job, the only pain in the ass is if the nuts and bolts are rusted. upper and lower headshields need to come off, the manifold bolts to the head with i think 9 bolts, and to the turbo with 4 bolts. the o2 housing bolts to the turbo with 3 bolts and another one of those giant pain in the ass studs, and to the downpipe with 2 bolts. make sure you have an o2 sensor socket to break the sensor loose, do that before loosening everything up because it is going to take some serious pulling to remove it at first. when you are putting everything back together coat EVERY threaded connection with high temp (2000 degree+ if you can find it) antisieze so next time it isnt such a pain. its also a good idea to get bolts to replace those studs since they are so incredibly annoying to work with.. your local mitsu dealer hopefully has a couple in stock to sell you.. um.. thats about all i can think of.. i just had my manifold off to port it last night and my buddy had his o2 housing off as well so all this stuff is pretty damn fresh in my mind

I guess ill wait till Sat. and do it with a buddy of mine. Its just my exhaust manifold is cracked, so it ticks REAL bad. and kids already give me beef because i love turbos(they are all muscle car freaks/truck freaks) So i know theyll be like "o is that ticking part of the turbo" I'll ust have to bring it back next friday and show em whats up.

 

[MyEclipse5]

Man i really want this done on Friday. I'll just either take off the heatshields and try that bolt thursday after work, or wait till Sat.

 

[saw wave analog]

good luck, i was running 19 psi last night when i got to my buddies house to port my manifold, when i was done porting and had everything back together that 19 psi had turned into 21, so it did definately increase flow. just make sure the transition between your manifold outlet is matched to your turbos inlet. if your manifold has been ported to 7 cm but your turbo inlet is still the stock 6cm the turbulence that will create may actually harm performance. i dont know anything about your setup but its something to keep in mind

 

[saw wave analog]

Man i really want this done on Friday. I'll just either take off the heatshields and try that bolt thursday after work, or wait till Sat.

its a good idea to break everything lose before going into the shop at school on a time limit. fighting with stuck bolts is the only time consuming part of the job. the stud on the o2 housing is even more of a pain in the ass than the manifold on is, may want to start soaking everything in pb blaster now and work on getting everything loose and ready to come out, then it should be no problem doign the swap in 2 hours.

 

[MyEclipse5]

good luck, i was running 19 psi last night when i got to my buddies house to port my manifold, when i was done porting and had everything back together that 19 psi had turned into 21, so it did definately increase flow. just make sure the transition between your manifold outlet is matched to your turbos inlet. if your manifold has been ported to 7 cm but your turbo inlet is still the stock 6cm the turbulence that will create may actually harm performance. i dont know anything about your setup but its something to keep in mind

I dunno what size the outlet of the new Exhaust manifold is, ill measure later. but i got the 6cm gasket.

 

[MyEclipse5]

its a good idea to break everything lose before going into the shop at school on a time limit. fighting with stuck bolts is the only time consuming part of the job. the stud on the o2 housing is even more of a pain in the ass than the manifold on is, may want to start soaking everything in pb blaster now and work on getting everything loose and ready to come out, then it should be no problem doign the swap in 2 hours.

I just checked my schedule...Tomorrow 4:30-10, Wed. 3:00-9:00, Thurs 4:00-7:00.

Shoot man, i amost have no time to work on this. I'll try thurs after work to losten the stuff up. but what tools will i need, i am limited BIG TIME. Beeing the first "mechanical" person in my familyi have basic screwdrivers, and socket wrenches.

 

[saw wave analog]

put the gasket on the manifold outlet. if the gasket does not exactly match almost exactly the size of the hole then you may have a problem. i had a ported o2 housing that was opened up to 3" bolted to the stock small inlet downpipe and the downsizing really hurt my top end, took it off the next day and went back to stock. not trying to scare you or anything just sharing my experience to hopefully save you some frustration (ive had plenty )

 

[MyEclipse5]

put the gasket on the manifold outlet. if the gasket does not exactly match almost exactly the size of the hole then you may have a problem. i had a ported o2 housing that was opened up to 3" bolted to the stock small inlet downpipe and the downsizing really hurt my top end, took it off the next day and went back to stock. not trying to scare you or anything just sharing my experience to hopefully save you some frustration (ive had plenty )

Well, its out in my car right now, and its dark, and i can't find a flashlight, ill check it out tomorrow.

 

[saw wave analog]

off the top of my head


the heatshield bolts are 12mm

the manifold to turbo and o2 housing to turbo bolts are 14mm

the manifold to head bolts are mostly 12mm, there are also 2 17mm bolts

the downpipe to o2 housing bolts are 19mm

the oxygen sensor itself needs a 3/4ths or (i think) 22mm o2 sensor socket to remove it while its in the car with the cable connected. it can be removed out of the car with a wrench and a big vise but its a lot easier wo get off when the housing is still bolted to the turbo.

thats about it.. this is all 2g specific as thats what i drive but to my knowledge there isnt any difference in the bolt sizes.. maybe a 1g guy can correct me if im wrong. basicly you need a full set of metric wrenches and sockets and a bigass breaker bar

 

[98FWDSM]

after doing a turbo install, i would DEFINITELY recommend that you spray PB blaster on the 4 bolts at the exhaust manifold and the bolts on the O2 and on the downpipe...i had a pain in the a$$ trying to get the downpipe bolts off...spray them down every day at least once for about a week, once you get started, you will be glad that you sprayed them down as much as you did

Good Luck