Tips for installing dump on Gen V
Posted: Fri May 30, 2014 9:48 amWent through the fun process of changing over dump pipes last weekend and just thought I would share a few tips if anyone else is attempting it (this is not a full step by step process just the things i remembered)
Tools required:
Good socket set and set of ring spanners
Good quality 14mm impact socket (for the dump bolts)
E-Torx Sockets to remove the studs
Screw drivers
CRC spray
Anti cease grease or copper grease
Bucket to capture coolant
Impact driver or Rattle gun (not essential but makes it alot easier)
1. Remove the two plastic covers under the car
2. Remove the steel heat shields covering the dump pipe
3. Remove the radiator hose inlet (where the thermostat is) which is in the way of one of the 4 bolts holding the dump (drain the coolant first by removing the phillips head plug on the bottom of the radiator)
4. Spray CRC on all the nuts and bolts you need to remove to free them up
5. Remove the O2 sensor which is closest to the turbo (I think this is in the way of something else, cant remember what)
6. Undo the plugs for the 2 sensors and remove the harness that holds the wires (can either remove the clips holding the harness or remove the whole harness (I think just a 10mm bolt)
7. Undo the bolts holding the first part of the dump to the rest of the exhaust
8. Remove two nuts (14mm) which hold a bracket which connects to the dump pipe studs (these nuts run verticle so are easy to get to with a ratchet and extension)
9. Undo the 4 bolts holding on the dump pipe to the turbo (this is the hard bit, as the nuts will be ceased from the heat). To make this easier use plenty of CRC, try doing it when they are still hot which I found helped or heat them up with a blow torch, and if you can get to them with a rattle gun or impact driver this will help to "crack" the rust (make sure you have a propper impact socket otherwise you will probably destroy the socket or the nuts), otherwise if you dont have one you can try just hitting them with a hammer to crack them. I also found with the top nuts if you use a long extension its easier to get access to them.
10. You may be able to remove the stock dump without removing the studs but I wasnt able to get the new dump on without removing them, so save some time and just remove them from the start using an E-Torx socket
The rest is easy, just do everything in reverse but make sure you use anti-cease grease or copper grease to help get the nuts off next time if required. Also when putting on the new dump dont tighten any of the nuts fully until you have the whole exhaust system bolted up, this will make it easier with alignment as there is a bit of play in all the joints if you tighten them before you have it all connected it might not line up right.
Again I may have missed some stuff but overall the hardest bit is removing the nuts from the dump, the rest is easy as long as you have time to do it. Have no idea why some people are saying the sub frame needs to be removed as I had no problems with mine besides the ceased bolts.
Tools required:
Good socket set and set of ring spanners
Good quality 14mm impact socket (for the dump bolts)
E-Torx Sockets to remove the studs
Screw drivers
CRC spray
Anti cease grease or copper grease
Bucket to capture coolant
Impact driver or Rattle gun (not essential but makes it alot easier)
1. Remove the two plastic covers under the car
2. Remove the steel heat shields covering the dump pipe
3. Remove the radiator hose inlet (where the thermostat is) which is in the way of one of the 4 bolts holding the dump (drain the coolant first by removing the phillips head plug on the bottom of the radiator)
4. Spray CRC on all the nuts and bolts you need to remove to free them up
5. Remove the O2 sensor which is closest to the turbo (I think this is in the way of something else, cant remember what)
6. Undo the plugs for the 2 sensors and remove the harness that holds the wires (can either remove the clips holding the harness or remove the whole harness (I think just a 10mm bolt)
7. Undo the bolts holding the first part of the dump to the rest of the exhaust
8. Remove two nuts (14mm) which hold a bracket which connects to the dump pipe studs (these nuts run verticle so are easy to get to with a ratchet and extension)
9. Undo the 4 bolts holding on the dump pipe to the turbo (this is the hard bit, as the nuts will be ceased from the heat). To make this easier use plenty of CRC, try doing it when they are still hot which I found helped or heat them up with a blow torch, and if you can get to them with a rattle gun or impact driver this will help to "crack" the rust (make sure you have a propper impact socket otherwise you will probably destroy the socket or the nuts), otherwise if you dont have one you can try just hitting them with a hammer to crack them. I also found with the top nuts if you use a long extension its easier to get access to them.
10. You may be able to remove the stock dump without removing the studs but I wasnt able to get the new dump on without removing them, so save some time and just remove them from the start using an E-Torx socket
The rest is easy, just do everything in reverse but make sure you use anti-cease grease or copper grease to help get the nuts off next time if required. Also when putting on the new dump dont tighten any of the nuts fully until you have the whole exhaust system bolted up, this will make it easier with alignment as there is a bit of play in all the joints if you tighten them before you have it all connected it might not line up right.
Again I may have missed some stuff but overall the hardest bit is removing the nuts from the dump, the rest is easy as long as you have time to do it. Have no idea why some people are saying the sub frame needs to be removed as I had no problems with mine besides the ceased bolts.
