Hi Guys,

Most of the howto's refer to taking your radiator out.

It would seem to me that just taking the exhaust manifold off is the easiest way.

Any gotcha's with this approach?

Also can I re-use the stock gaskets and bolts with the "ebay" dump (V2 Titek basically) Or should I really get new gaskets?

Cheers
D

 

Be VERY prepared to bust up your radiator with this method unless you put some thick cardboard over it while working in that area. Don't ask me how I know.

-E

 

yes I will protect it from tool knocks and such.

are there any other gotcha's?

It would appear thou the hardest bolt to gain access to is the one hidden by the outlet pipe on the dump itself - however I am hoping it's fairly trivial to get to this one from below.

Will the stock bolts AND gaskets be fine for re-use? my kit didn't include anything except for the dump :|

 

I think you have a general idea of what this is going to entail.

I would strongly recommend possibly removing the hotside and attaching the dump that way. I just know you're going to be cussing up a storm if you attempt it the way you are wanting to.

I'm one of those guys that likes insurance. I would recommend replacing the gasket at least. The bolts, you'll have a better chance of betting on the Lottery with that one. I have YET to see anyone be able to re-use all the stock bolts again without snapping them, stripping them, or shearing them.

Good luck!

-E

 

I have done this from above with the radiator still in the car. It is a PITA and it took forever. I really should have just dropped the rad and pulled the turbo just to make things easier.

As for the gaskets, they are all metal so if they appear fine why not re-use them?

Oh and spray the heck out of all the bolts with some BP blaster. These things are tight. Wratchet wrenches will be your friend too.

 

did u take the exh mani off?

 

If I recall correctly I believe I did. It was the only way to get to the inner upper bolt on the O2 housing off. Oh and it makes getting the O2 Sensor out so much easier.

Here is what I would do....

Disconnect the DP
Remove the lower IC pipe
remove the mani bolts
Disconnect the Intake pipes from the turbo
On the stock O2 there is a mounting bracket under it....remove it
Remove the mani
Disconnect the oil and coolant lines from the turbo
Disconnect the oil return line form the turbo side
And finally pull the turbo and O2 as one part

You can do all of this and leave the Rad in the car. It sounds like a lot, but is is quite easy. Once you do it I am sure you will agree.

Heck, since the turbo will be out you can go ahead and gasket match the hot side and open up the flapper hole a bit to help with boost creep.

Make sure you can roll a golf ball through the new O2 housing on the waste gate side. This will ensue you minimize boost creep.

Paul

 

Tephra, does dump = O2 housing?

If so i have done this twice without removing the radiator. I removed the exhaust manifold, downpipe, and took the hotside off the turbo (1 vband clamp) and did the rest off the car. It makes things a LOT easier. Feel free to email me if you have questions.

You can reused all of the gaskets with exception of the exhaust manifold to head gasket, i would replace that one. Be careful though, it is razor sharp. I have a nice scar to remind me of that.

 

I also split the turbo. I PB blasted all the bolts and was able to reuse all the stock bolts. I would recommend removing the radiator. Not only for it's protection, but you'll have that much more room to work with.

Use hi temp copper gasket spray and the stock gaskets will be fine.

 

lol itsssss a PITA! And if you split the hotside make sure you line the little pin back up that goes from the compressor side and the hotside b4 you tighten the clamp up..IMO id drop the rad. Just so you dont have the chance to put a hole in it. And PB BLASTER is your best frined like everyone else says...its def a pain but not to bad.

 

I vote pull manifold / hotside out and then put all back together on a bench and re-install. Put a heavy piece of cardboard over the radiator and all will be good. I did it this way on mine and it was really easy.

Also I would use all new oem gaskets, they are inexpensive and worth just doing the first time around.

 

tephra- its so easy to take out the radiators on these cars, it would be silly not too. it will free up a lot of room for the stubborn bolts.

 

+1 i think he is correct because if you try to pull the stock 02 bolts out with a wrench ur gonna break em. Use pb let soak then run out with an air gun.

 

I've taken off the O2 Housing so many times I could do it in my sleep. First Take the Radiator out, it only takes 3 minutes. It frees up so much more room to work above the car not below it. Get the Motor Hot but not crazy hot, spray PBlast liberally, let sit overnight. Have you a swivel socket adapter, will save you big time in effort. Also would help if you had a shorty 14mm open end wrench for that bottom near engine nut-on-stud.

 

Obviously not in this order