Downpipe removal on LCR

[NeilC]

I was trying to fit my exhaust today and cant see a way of getting the dp out from the car
I've undone the bolts from the manifold but when i try and wiggle it out it wont go as its tight against the steering column at the back of the subframe.
Do i have to drop the front subframe and swing the steering rack down to make more room (i've already undone the bolts and drained the power steering fluid to make more room)?
Or is there another easier bit that needs to come off before i can get it out?

 

[Songman]

I was trying to fit my exhaust today and cant see a way of getting the dp out from the car
I've undone the bolts from the manifold but when i try and wiggle it out it wont go as its tight against the steering column at the back of the subframe.
Do i have to drop the front subframe and swing the steering rack down to make more room (i've already undone the bolts and drained the power steering fluid to make more room)?
Or is there another easier bit that needs to come off before i can get it out?

Definitely came out of my car without dropping subframe - it was a frustrating job!! - we cut lower mount arm on the downpipe and eventually with patience found a angle and a path to get it out from underneath

The APR downpipe fitted up no problem

Some folks however, like to drop the subframe and be done with it

 

[NeilC]

Did you get it out by twisting it and bringing through the transmission tunnel, or did the removal of the exhaust hanger bracket allow you to spin it round and bring it down between the bulkhead and the subframe?
Why do they make things such a stupid shape! As im bringin it down atm there seems to be a metal bar in the way (looks like part of the turbo actuator?)

If i just know the angle you bought it out at it might give me a fighting chance!

 

[Songman]

Did you get it out by twisting it and bringing through the transmission tunnel, or did the removal of the exhaust hanger bracket allow you to spin it round and bring it down between the bulkhead and the subframe?
Why do they make things such a stupid shape! As im bringin it down atm there seems to be a metal bar in the way (looks like part of the turbo actuator?)

If i just know the angle you bought it out at it might give me a fighting chance!

Aye Neil
I watched whilst the mechanics cursed and swore under the ramp!!- thinking ` thank God I don`t have to do this myself!`
I`m pretty sure they manoevered it around and eventually fed it out between the bulkhead and the subframe, following the `natural path` so to speak, twisting around and down out through the transmission tunnel aperture, at an acute angle -- the support bar on the old manifold stopped it from coming out completely, so they cut it - they raised the engine a bit with a transmission jack too - the new pipe went in the same way as old one came out

 

[NeilC]

Cheers! I'll give it another bash tommorow. I have to admit after spending about 2 hours swearing at it i started looking at the exhaust cutter thinking hmmmm Then i remembered the amount of time it took to cut the backbox off and figured it would be thicker at the DP (bet it's ace on pizza tho).

 

[NeilC]

Anyway i thought i'd better round this post up incase someone else decides to fit an exhaust themselves (dont! - thats all i have to say).

In all it took me about 2 days on and off although i reckon i could have knocked some time off by droppig the front subframe stright away.
But basically i ended up lowering the subframe on the bolts (supported on a jack) which gave about 15mm whcih let me get the dp out to a point. Then cut the hanging bracket thing off as songman suggested to get it all out.
Started it up with the bonnet open and left it running for a bit to let the condensation out the back and burn off the wd40 on the bolts on the front and all was well.

Then all the power steering fluid p*ssed out the bottom of the car!
Turns out seat only put a copper washer on one side of the bango connection from the power steering pump to the steering rack so it couldnt seal on the steering rack side because it would be 2 bits of aluminium pressing together (obviously the factory robots can press a bit harder than us mortals!). Took me about a week to find someone who'd sell me a 14mm copper washer, but i put it on yesterday, filled it up with power steering fluid and it was fixed!

So i took it out for a test drive and after letting it warm up for a while put my foot down. After 7k rpm i heard this psssss - BANG noise followed by what seemed like the gasket on the manifold blowing So after cursing seat for selling me something that only lasted 1 hour i limped home.

Took me about 20 mins to find the culprit. What looks like a temperature sensor screwed into the back of the turbo had popped out! Luckily it hadn't taken the thread off so i just screwed it back in. I have some before and after logs to post when i get in, but does anyone know what this sensor is for and how it managed to force itself out when its threaded?

 

[NeilC]

Anyway here are some logs. Maf seems to have gone up about 9g/s, and it now feels like it comes on boost earlier which is nice
Unless it's knackered? Thought it was supposed to be in the range 190-205?
I know i could increase the timing a bit but i'm booked in for stg 2 on sat so that'll prob alter things anyway.

stg 1 only

stg 1 + full system