GT exhaust manifold install questions?

[dzolcali]

Hey guys, I recently got the GT manifold from turbochargers.com, but i'm having trouble getting my old manifold off. I got the head shield off, and then took the top four head nuts out, got one of the bottom nuts out but i'm having trouble getting access to the others.
Also the four main studs that connect to the turbo, i tried to take one off and even after using pb blaster that thing was solid...i read somewhere it may be reverse thread does anyone know about this because i am really not wanting to pay 300 dollars to have a 150 dollar manifold installed.

I really need some detailed instructions on how to do this but so far i haven't had any luck...

thanks guys

 

[big_eskimo]

Hey guys, I recently got the GT manifold from turbochargers.com, but i'm having trouble getting my old manifold off. I got the head shield off, and then took the top four head nuts out, got one of the bottom nuts out but i'm having trouble getting access to the others.
Also the four main studs that connect to the turbo, i tried to take one off and even after using pb blaster that thing was solid...i read somewhere it may be reverse thread does anyone know about this because i am really not wanting to pay 300 dollars to have a 150 dollar manifold installed.

I really need some detailed instructions on how to do this but so far i haven't had any luck...

thanks guys

Ok,
As for the bottom manifold to head nuts, you can use a flex socket to gain access to the far right one (I found this was the only one I needed a flex socket for) also use a long extension, it helps with being able to use the space in front of the turbo for your ratchet. As for the stuck bolts, try putting mad PB Blaster on, I used half a bottle to get my turbo and exhaust manifold off, let it soak for a long time, at least an hour or so, I've heard some people let it soak overnight. As for the threads being backwards, it may be different on your 2G, but mine were standard threads. Keep us posted.

 

[crunchymilk]

I used a long extension, didn't have any problems.

To help those bolts get out, try soaking them in PB plaster and then turning the car on and letting it get hot. The heat causes metal to expand. After you turn it off wait a few minutes and then spray it again. Repeat this until they come out, eventually it should be easy. It worked for me. My 3 turbo bolts and stud came off easily without breaking.

 

[larsrya8]

When I did my turbo install, the first thing I did was take off the shields and soak all the bolts with penetrating oil. I put a 6-pointed socket on the top of the turbo with the wrench and tried to turn it. I found that using a piece of pipe to lengthen the handle a few extra inches was all I needed... but that does increase the risk of snapping the bolt in half.

If the engine is already disable for whatever reason (drained oil or something) just use a torch to heat the bolts up if the penetrating oil doesn't work.

The bolts are not "reverse threaded".

 

[HIGHPSI4]

It is not that detailed. You just have to have the right tools and make it work. There are several carolinadsm guys in Charlotte. I may be there this week looking at another DSM.

 

[Newlogics]

Your best chance of removing four turbo bolts is to use a boxed end of 14mm wrench (with a bar or another wrench for leverage). Soket will strip the bolt eventually. Also, sometimes it helps to first tighten it a bit and then go reverse. Going back and fourth all the time will save you from cross-threading it.

As for the rest of manifold studs, one on the left, and one next to it is accessible via 6" extension and a small ratchet. So is the second one from the right (P/S side)
The one in the middle (behind turbo) is accessible via a regualr 12mm wrench (make sir to use boxed end), and one right next to P/S pump sometims will come out with a flex-socket, but you may have to pull P/S pump off to the side to get at it.

Please make sure you take car of four turbo bolts BEFORE you pull all exhaust manifold studs, or else you won't have a solid hold on the manifold, and it will make your job much harder.

 

[2fast4]

I'm not sure if you took fans out of the way. Socket extension won't fit well with it in. Also, the turbo should be taken off, or lowered w/ bolts and stud out. If I were you, I'd permanently remove the stud out and put all 4 bolts, for future user friendliness. Use 2 same size nuts and turn the lower one to take it out...PB blaster too.

 

[snox135]

You do not need to remove the turbo to get the manifold off or on. I used a gearwrench to remove the nuts I couldn't reach with a socket.

PB Blaster does work good but I have never found anything that works as good as AeroKoil.

 

[dzolcali]

ok so far I got everything off, four main studs were a breeze with the bar...pb blaster worked very well on all the other stuff..

heres my issue..the center one that is to be used with a box wrench...because of the angle I couldn't use a box wrench, so I used a closed ended 12mm instead, which turned a little funny because the valve cover was in the way...anyways it cause the top of the nut to slightly strip..so now I can't turn the nut unless I get it from a different angle..I haven't even gotten this one loose yet so I need leverage if ima turn it.

also do I need to remove the studs before or after the manifold is off...because a few of them have already came out, a few stayed in...will the manifold basically just come right off if I take the main four studs out of the turbo and unbolt all the tiny 12mm nuts?

i'm really confused reading all the tech articles but I refuse to pay 300 dollars for someone else to do this...

I need some help if anyone has good advice or experience.
peace

 

[mirkoelek]

Just spray with some water and those 4 bolts will come out easy

 

[dzolcali]

one of the bolts has a nut on the top..the other three are facing down...does the nut on the top indicate that I have to push that bolt down through something because I felt up under there and didn't feel the other end of that bolt..

also if i take the main four bolts out, I read in a vfaq theres like a ring to line the turbo and the exhaust mani together and you have to do all this stuff to get it out? is this true or no on the 2g's?

I think I might give it another go tommorow if I can get the one middle nut off, and do I have to remove the studs or just get the nuts off thats really my question more than all others