Down Pipe Install - Please Help - Video

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awolo

New member
Hey guys. I know your probably thinking, "oh great, another down pipe install thread"....well, yeah.

I need some advice on what to do next. Please disregard my dirty a hell engine bay. She is getting a complete overhaul soon!

I cant keep breaking bolts and parts, its getting redic. :bangshead:

Click my vid:



Link:
http://s285.photobucket.com/albums/ll56 ... 53_772.mp4

Any advice/guidence is much appreciated. :notworthy:
 
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jaydog82

New member
The vid did not work, post a link. Once u remove all the bolts for the do then remove the oil filter and work on dropping the do down by twisting and giggling it should go down and towards the driver side.
 
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celigts

New member
K so from my phone all I get is a pic and as far as the pic goes looks like you still need to remove the oil filter, loosen the manifold bolts and you should win.
 
A

awolo

New member
I posted a link.

You have to click on the pic.

Anyway, I have the manifold bolts all the way loose and I still cannot get the down pipe out. Its not hitting on the oil filter. Its hitting on the filter housing where it screws in.

Ive tried EVERYTHING to wiggle it out. I just cant get it over the bottom two studs that hold it to the turbo.
 
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Corey

Active member
When I removed mine I had my motor out, but I recall removing the Cat from the upper portion of the downpipe first. If you can remove that bottom section first, it might help.

Edit: NM just watched the video lol I see you already have it off....

I'd also suggest removing that filter - it can't hurt. If you're really desperate maybe you can use a hacksaw to shorten some of those studs a bit. Then to replace them you can thread a couple nuts onto the shortened studs and use the inside nut to back the stud out. Might as well replace the studs while you are there, they are cheap from toyota.

Orr since you already have the exhaust manifold loosened up, you may want to replace those gaskets. So might as well just remove the entire turbo/manifold/downpipe in one piece. That's how I reinstalled my setup while the motor was out. I installed the KOracing downpipe to the turbo first, then installed the whole setup to the engine with new gaskets.
 
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loudstealthGT-Four

Member
you could try,

cutting the ends of the two studs that are causing you greif?

removing the two studs (if that would be easier than cutting/ would recommend giving the studs a good spray with a anti-seize/penetration lubricant)

or if everything else fails, bash it with a hammer (usually sorts things out :evil: :D )
 
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BoostedBlueToyotas

New member
Its been awhile but I am pretty sure you have to move the oil cooler (the base under the oil filter). You have
to remove the 30mm bolt holding the oil cooler to the base. Since putting this back together is a pain (Its almost
impossible to rethread that big bolt back in without crossthreading it into the pewter base which then cracks and
then you have to replace it). Note that is with the stock DP only, aftermarket ones dont have the clearance issues that the cast iron stocker does

Maybe you can loosen the exhaust manifold and slide the manifold/turbo/downpipe forward enough to give you
enough clearance to slide the downpipe off. Just watch so you dont kink the water and oil feed lines to the turbo
if you try this.
 
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4rsnduction

New member
Since you have loosened the bolts that hold the exhaust manifold onto the head you might want to use a fresh gasket
Your going to need to remove the turbo and its water/oil lines and exhaust manifold anyways, doing all that should get your dump pipe out by default, also gives u good chance to inspect everything.
 
A

awolo

New member
This is all GREAT information.

I don't have the parts to replace the exhaust manifold gasket of that damn stud I broke.

I have loosened up the Exhaust Mani bolts, but the manifold only comes out to a certain point. If I had another 3mm I could get it off. But im not sure whats stopping the manifold from moving. Maybe the turbo and what not.

I need to be able to drive the car by Monday for work.

Looks like i'm going to spend my Saturday under the hood.

And I havenet even gotten far enough to figure out getting the mid-pipe over the sub-frame.... :|
 
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celigts

New member
Could be the turbo oil lines not letting you move far enough out. I also took the dp out of the mid pipe for more movement. If you haven't done that either.

Kind of off topi but can the exhaust manifold be moved out enough to replace the gasket without removing the turbo? Don't think so eh?
 
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Corey

Active member
You'll need to unbolt the oil line from the block (will need to replace both gaskets for the banjo bolt) and there is a turbo support bracket holding the turbo to the block which will need to be undone. You may need to disconnect the upper rad hoses but they might be flexible enough.
 
A

awolo

New member
It seriously cannot be that intricate to get the down pipe off. All the searching I did, didnt even mention removing the turbo and all this.

If I new I was going to have to replace all these bolts, gaskets and remove the turbo, I would have waited till I had all the parts and done this right.

Sh*t.

Well, its 7:41am....time to start.
 
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loudstealthGT-Four

Member
It can be done without removing the turbo.

When I swapped mine to an aftermarket one I didn't have to,

remove turbo
loosen off the manifold bolts.

Only problem is, I can't remember what I did to get it off, I think i may have just cut a couple (mm) off the end of the stud that it was catching on?
 
C

Corey

Active member
It might be the case that when those old crusty nuts are removed from the studs, a few studs get pulled out along with them. This would really help with removing the pipe

I think the easiest way would be for you to start cutting up studs (make sure to leave enough thread on them to remove with 2 nut method)
 
A

awolo

New member
Well, 3.5 hours later and a crushed finger...

....now...to start the cat-back system...first thing, loosening up the lower sub-frame...
 
A

awolo

New member
Full 3" turbo back exhaust....installed!!

2012-07-14_11-10-27_349.jpg
 
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awolo

New member
Took the car for a spin.

She makes boost all the way to 15 psi, but she doesn't have that kick.

I think that broken exhaust manifold bolt/stud is leaking all my boost.

This sucks.
 
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