Im going to attempt the dreaded Downpipe!

[mr2turbo99]

Ok guys ive been doing hours of research, finding some really good information and some horror stories regarding this modification. I feel its time that i attempt this one now on my Rev 1 turbo, but before i do i require some facts about doing the job. I have searched through stacks and stacks of posts on downpipes, on here and on other forums. some of my questions have been answered others haven't so here we go.

My arsenal for the Job includes an unlimited range of good quality tools and two ex military engineers and of course myself (probably to direct)

1) Will i have to remove the oil filter and oil cooler resulting in oil change.
2) Is there any coolant removal involved
3) What are the hardest bolts to get too
4) Which bolt(s) are likely to snap/shear
5) Once the DP is installed do the Heat shields go back on
6) Do i need to move the dipstick out the way
7) The engine had a HG change last year as well as head work a few years back, would the turbo/cat e.t.c have been removed to do this work and will this make the job easier as these components haven't been locked down since the car was born?
8.) Should i heat wrap my DP
9) If i cant remove the cat will the Mongoose zorst im planning to fit bolt to the cat.
10)Whats the worst possible thing that could happen doing this job?

Sorry for all the questions, some may sound a bit stupid but "if you dont ask, you dont get"

I must also stress this is for a Rev 1 tubby.

If youve read this far i really appreciate you reading and i hope you can help me out. Thank you

[Baker]

fella, for a measly £80, get skywalker to do it.

The first snapped stud will make you pick up the phone to him though!

[mr2turbo99]

i hear what your saying and that thought did cross my mind but ive done everything else on my motor apart from this. Are the bolts really that bad?

[mr2turbo99]

ive just been reading through my car history file and ive spotted back in 2007 the whole exhaust, cat, manifold turbo assembly had been removed and replaced using new bolts/studs/nuts. Ive read most problems are experienced removing the cat because the bolts havent been undone for the cars life so because my cat definitely has been removed not so long ago are my chances of this going well increased?

[Chris]

Save your knuckles. I reckon if them bolts had been out a week ago, they'll snap! I wouldn't do job for £80...Luke is tooo cheap

[dansREV2turbo]

did mine in about 31/2 - 4 hours on my first attempt. get stuck in!

[dansREV2turbo]

buy a 14mm offset ring spanner. makes it alot easier for one of the bolts

[mr2turbo99]

Got all the tools for the Job im still convinced we can do it especially after my recent discovery of all the bolts e.t.c being replaced. Can anyone answer the questions i posted earlier especially the ones about the oil filter/cooler and coolant?

[platmatt8]

jeffd has done a great write up some where have a search.



edit*

here it is but just realised the rev difference.
http://www.imoc.co.uk/forums/viewtopic. ... ntercooler

Remove the oil filter defo, i suppose you could remove the dip stick as it`s only one bolt, the oil cooler is a 30mm nut but i think you`ll get away with leaving it in place.

[mr2turbo99]

forgive me if this is a dumb question but if i remove the oil filter will i lose a lot of oil?

[JeffD]

I did this on my rev3 (oil filter in different place) so will try and answer best I can but would recomend reading my writeup too.

1) Will i have to remove the oil filter and oil cooler resulting in oil change.
On a Rev1 I believe you have to take the filter out as it gest in the way.

2) Is there any coolant removal involved
I didnt on mine so as a guess no unloess something is radicly different on rev1/2.

3) What are the hardest bolts to get too
Looking from the back the bolt nearest to you holding downpipe to exhaust elbow is a right pain and requires a 14mm swan neck spanner.

4) Which bolt(s) are likely to snap/shear
None - use plenty of wd40 the night before - they may round on the heatshields etc though. I wouldnt attempt this job unless yoiu have a set of Irwin bolt grips.

5) Once the DP is installed do the Heat shields go back on
Ive not put mine back.

6) Do i need to move the dipstick out the way
I did for access with wrench but its held on with a bolt and then you can swing it out way whilst leaving it in place.

7) The engine had a HG change last year as well as head work a few years back, would the turbo/cat e.t.c have been removed to do this work and will this make the job easier as these components haven't been locked down since the car was born?
If the components have been removed before it should make life much easier.

8.) Should i heat wrap my DP
Not done on mine and Ive heard that they can trap damp and accelerate corrosion.

9) If i cant remove the cat will the Mongoose zorst im planning to fit bolt to the cat.
The exhaust front flexi mates up to eith the stock cat or a downpipe in the same place.

10)Whats the worst possible thing that could happen doing this job?
Youll lose the will to live 1/2 way though! LOL

Its all down to tools this job! Make sure you have a good selection of sockets, deep reach sockets, swan neck spanners etc.

Id also replace the gasket between the turbo and elbow/downpipe at the same time.

[mr2turbo99]

Thanks for the great info! much appreciated. I guess thats all i need to know. i will be attempting this on saturday so wish me luck!!!

[RobCrezz]

Just go for it. I managed to do the downpipe and im xxxx at all that.

[AndyBrad]

Took me 4 hours on my own.

KORacing have guide for the earlier revisions

[Steve-O 2007]

Never done anything like this before and Im not a mechanic and I managed to do it myself on a saturday Oh I have a Rev2 Turbo same as Rev1 I would say

1) Will i have to remove the oil filter and oil cooler resulting in oil change.

I only had to remove the oil filter so no oil change needed

2) Is there any coolant removal involved

No

3) What are the hardest bolts to get too

ones closest to the engine are worst I would say but just get the car up in the air as some you can only get to from under and some are easier to do from under.

4) Which bolt(s) are likely to snap/shear

They all have a chance. I can guarantee you if one does snap it will be one of the hardest ones to get to, alwasy seems to happen like that lol.

5) Once the DP is installed do the Heat shields go back on

No, but the top one does that covers the manifold

6) Do i need to move the dipstick out the way

I undone the dipstick holder and moved it out the way. Took almost an hour to get that anoying bolt back in that holds it!! That was a pain lol

7) The engine had a HG change last year as well as head work a few years back, would the turbo/cat e.t.c have been removed to do this work and will this make the job easier as these components haven't been locked down since the car was born?

Noticed you have already found proof that its all been off in 2007, thats good news as it will make the job alot easier.

8.) Should i heat wrap my DP

I didnt do mine as apparently it can cause them to crack easier

9) If i cant remove the cat will the Mongoose zorst im planning to fit bolt to the cat.

Yea should do, But you will get it off anyway so dont worry about that Just dont give in

10)Whats the worst possible thing that could happen doing this job?

Cut fingers / nuckles and lots of pain. Oh and Bolts snapping


Luckilly when I replaced mine the old cracked Downpipe had only been on for about a year (5,000 miles of use) so the bolts came off quite easy hopefully yours will be the same

What dp are you getting?

Heres some pics of the bolts that might help -

[Charged]

Good luck fella!

I guess Skywalker can afford to do them at £80 as he does so many and therefore does then very quickly.. I remember he did the downpipe on my 1.5 in under and hour.. and the access in a 1.5 is even more limited than in your probes!

[Steve-O 2007]

than in your probes!

hey, get back into the Mk1 section if your going to carry on with that offensive language lol

[C50]

good luck! if it's been removed before.. it's really easy

you'll be fine just let it soak with some penetrating oil to be on the safe side

[mr2turbo99]

Just like to say, thanks for all the great advice. I feel like i stand a better chance of doing this now! Cant wait to get stuck in!

[mr2turbo99]

Oh forgot to mention. Not sure the make of the DP. I bought it off a chap who had it on is CT26 hybrid, he also sold me the zorst too. Just looking at the photos on this thread ive noticed it looks quite tight between the oil filter and the corner of the downpipe. How much clearance is actually there?