Install of new 4" exhaust

[christja]

When installing the new downpipe, do you have to remove the turbo? or does it drop out the bottom? Would it be easier to install new glow plugs and injectors at the same time? Ive read some threads that suggest removing the fender to access the plugs and injectors on the passengers side...i just want to eliminate unnecessary work :) :confused:

[Chevylover]

When installing the new downpipe, do you have to remove the turbo? or does it drop out the bottom? Would it be easier to install new glow plugs and injectors at the same time? Ive read some threads that suggest removing the fender to access the plugs and injectors on the passengers side...i just want to eliminate unnecessary work :) :confused:

No, for installing the downpipe you have to remove the OEM Airfilterbox, than you got enough space to losen the clamp that hold the downpipe in position at the turbo back. For glowplugs i would prefer to remove the iner fender or try to them through the splash guard . The injector could be exanged without removing the turbo, but it will take a little longer and you should have special equipment - In germany we call it crow foot.

Cu,
Sven

[christja]

Thanks Sven, Its called crow foot here as well. Do you think i could get it all done in 1 day?

[Chevylover]

Thanks Sven, Its called crow foot here as well. Do you think i could get it all done in 1 day?


All in one Day shouldn't be a prob. For the exhaust with removing the stock one first by flexing, i need about 2 hours. working normal not fast ! The injectors AND glow plugs should take about 2 hours. The glowplugs passenger side through fender / splash guard should take not much mor than an hour. The injectors on passenger side will last much longer. We need about 5 hours to exchange all incl. fuel return lines on this side, but without removing turbo or something else.

So you should calculate with about 10 hours for all.

Cu,
Sven

[3bals]

Chevylover is right about the time. I did it last spring. Although I removed the turbo to get at the injectors. I installed the new down pipe and exhaust at the same time. This fall while I was replacing the IP, I also did a compression test. That required me to access the glowplug ports to screw in the test probe. That also ment removing the down pipe. I found that from this spring to this last fall, the pipes became almost as one. After some creative pulling twisting and swearing, they came apart but I ended up dropping the whole exhaust down. To eliminate that problem in the future, I cut the pipe right after it turns horizontal and welded on a pair of header collector flanges that I got from Summit Racing. Now if I need to drop the down pipe, all I have to do I remove the clamp from the turbo and the 3 flange bolts. Oh, and don't forget the high temp anti-seize.

Jody