Downpipe removal and reinstallation

[neilw]

Is it possible to do this with only one person, or is it a struggle and better to have help?

[Cadders96]

Far easier with help, to get access to some of the downpipe bolts you should remove your battery and intake, this will allow you to use a extension for a socket to get to a bolt easily.

[MIJ_JAGGER]

Top 2 bolts and sensor are accessible just by removing the intake

[Paradox1]

You can definitely do this yourself. remove intake. You can get to the 4 downpipe bolts from ontop of the engine.

Jack it up. undo the 2 exhaust hanger bolts then disconnect the V band.

[neilw]

Thanks, Yeh I had a good look when I had the engine cover off. I can see the O2 sensor and two bolts they look reasonably easy to get to. I wondered if you can get the other two from underneath.

It's more the lifting and maneuvering it out by myself I worried about, I don't want to get stuck with it off the car.

[MIJ_JAGGER]

Thanks, Yeh I had a good look when I had the engine cover off. I can see the O2 sensor and two bolts they look reasonably easy to get to. I wondered if you can get the other two from underneath.

It's more the lifting and maneuvering it out by myself I worried about, I don't want to get stuck with it off the car.

Word or warning....The studs/nuts are notoriously known for snapping off...

[Paradox1]

just unplug the 02 sensor and drop the loom down by the exhuast. to remove the actual downpipe, you need to rotate it and remove it. simple once your there.

Only negative thing that can happen is the turbo bolts backing out or snapping.

[neilw]

Thanks, Yeh I had a good look when I had the engine cover off. I can see the O2 sensor and two bolts they look reasonably easy to get to. I wondered if you can get the other two from underneath.

It's more the lifting and maneuvering it out by myself I worried about, I don't want to get stuck with it off the car.

Word or warning....The studs/nuts are notoriously known for snapping off...

What's the process involved it sorting this if it happens? I'll feed them some anti-seize the day before.

[Paradox1]

If they snap in the turbo then youd need to use an extractor to get it out I think.

Put some fluid on it a hour or so before your remove the studs. I didnt use an impact tools for this reason. Ratchet will do.

May also be worth changing the gasket while your there

[MIJ_JAGGER]

I had the one closest to the engine snap on me, which is the slightly awkward one to get to when trying to remove the snapped stud....plenty of heat, like glowing hot then twist out, it's a real pain.
I done my downpipe install on a lift so made life a little easier...
Good luck

[MIJ_JAGGER]

Part numbers if you need em

Stud: N0445203
Nut: N10286108
Gasket: 1K0253115AB

[neilw]

I had the one closest to the engine snap on me, which is the slightly awkward one to get to when trying to remove the snapped stud....plenty of heat, like glowing hot then twist out, it's a real pain.
I done my downpipe install on a lift so made life a little easier...
Good luck

Thanks might just get the parts ready on stand by.

http://www.halfords.com/workshop-tools/tools/hand-tools/laser-impact-stud-extractor-1-2-drive Is this the correct tool for taking out the studs?

When you say you applied head did you do so to the bolts to free them or just the stud once it goes bad?

[MIJ_JAGGER]

I didn't have an extractor tool, just used grips, done it on a Sunday so couldn't get tools.
I used heat on the snapped stud and surrounding wall.
The extractor will probably make it easier, grips took ages!

Worse case scenario, it snaps and there isn't enough thread to grip onto with grips or the extractor....that would mean drilling?

Hopefully yours doesn't snap!

[Octoparrot]

I was thinking of doing this myself recently but was concerned about access and a stud snapping. I got the engine up to temp and let it cool until the downpipe was still warm to the touch. The top 2 can be got at by removing the air box but the one nearest the engine is by feel only. I sprayed plenty of plus gas on the studs and then using a 16mm socket with an extension I ran another nut down and back up the stud to try to help clean the thread up a little and then GENTLY loosened the nuts and both came off without too much trouble. I did the same on the lower ones which are easily accessible from underneath once you've removed the cv joint heat shield. If you need to remove the O2 sensors it may be better to do it with the downpipe in situ as they can be extremely difficult to unscrew. Probably a job to tackle when you've plenty of time and won't need the car in a hurry should anything go wrong!
The nuts are N90369001 and are £5.85 +vat each the gasket is 1k0253115AB and is £6.63 +vat

[neilw]

I was thinking of doing this myself recently but was concerned about access and a stud snapping. I got the engine up to temp and let it cool until the downpipe was still warm to the touch. The top 2 can be got at by removing the air box but the one nearest the engine is by feel only. I sprayed plenty of plus gas on the studs and then using a 16mm socket with an extension I ran another nut down and back up the stud to try to help clean the thread up a little and then GENTLY loosened the nuts and both came off without too much trouble. I did the same on the lower ones which are easily accessible from underneath once you've removed the cv joint heat shield. If you need to remove the O2 sensors it may be better to do it with the downpipe in situ as they can be extremely difficult to unscrew. Probably a job to tackle when you've plenty of time and won't need the car in a hurry should anything go wrong!
The nuts are N90369001 and are £5.85 +vat each the gasket is 1k0253115AB and is £6.63 +vat

Thank you, that gives be abit more confidence.