WTF is the deal with those 3 studs that hold the DP flange to the hot side? You cant get the downpipe on!!!!! Everyone switch to bolts or something and forgot to tell me?
PLUS... WTF is the deal on the manifold! same problem, bolt holes are to close to manifold runners to get the nuts tightened to spec torque! can get them on but have to use a wrench to tighten.

ARRRRGGGHGHHGHHH!!!!!!!!!!

The dp is tricky. Put the dp on the turbo first, make sure you put the studs in the right way and put all three nuts on before you torque any of them down. It's no too hard. Your a bright guy, you can figure it out. :P

The manifold is a bitch. They made the runners very large. Just use a wrench to torque the bolts. Don't use those bullshit allen head bolts HRC supplies. make sure you use high quality bolts or studs. I had 8.8 grade bolts and the mani would just pop the head right off of them. Torque the bolts to about 20 ft/lbs by hand. Snug the bolts and torque them from the inside torwards the edge. Check them all after a few heat cycles.

Originally posted by etx
Don't use those bullshit allen head bolts HRC supplies. make sure you use high quality bolts or studs.

^^ I agree. I had the heads snap off of 3 of those allen head bolts that came with the kit. I went to my local dealership and got exh mani studs, washers, and nuts for the 4g63.

I went to Napa and just got the right size studs, and regular nuts, both are metric. Came to around 8 bucks, and have not had one issue yet. Prob going on 15,000+ miles so far..As for the DP, its really not that hard. I highly suggest to remove the passenger radiator fan, as this really gives you room to work. Put the BOTTOM nut on the DP first, and leave the DP NOT touching the turbo. Then as you start to thread the bottom nut on, slowy pull the DP along with the nut until it touches the turbo. Works every time, and is very simple to do..I guess I just dont understand why so many people have a problem with it :shrug

well, i ddid use grade 8 studs all the way around on the manifold, but theres not a lot or wrench room in there..

on the DP, does the longer thread end of the stud go into the hot side and the shorter thread end go towards the DP? anyone use thread locker, or is it needed?

Yea...those are the tough spots of the kit...heh besides the FCD and FPR.

Use a stubby 15mm (I think) wrench t get that downpipe bolt. The upper 2 bolts should be cake. But that 3rd one is a bitch to get to- however with a short stubby 15mm wrench you can do it without much problem.

For my exhaust manifold, I used 4G63 studs and nuts...had them before the HRC even hit my doorstep cause I had heard of stories.... Torque them down with a 12mm wrench....drive it hot..then re-tighten. Keep an eyes on the outside ones...they are prone to loosening up.

:thumbsup

Originally posted by tim97rs
well, i ddid use grade 8 studs all the way around on the manifold, but theres not a lot or wrench room in there.. on the DP, does the longer thread end of the stud go into the hot side and the shorter thread end go towards the DP? anyone use thread locker, or is it needed?

long end of the stud goes into the turbo,no thread locker needed

Originally posted by XtremeRS
As for the DP, its really not that hard. I highly suggest to remove the passenger radiator fan, as this really gives you room to work. Put the BOTTOM nut on the DP first, and leave the DP NOT touching the turbo. Then as you start to thread the bottom nut on, slowy pull the DP along with the nut until it touches the turbo. Works every time, and is very simple to do

I agree. I've taken off my manifold/downpipe many times, and the method described ^^^ is the way to go.

i ended shaving that bottom nut down a bit with a dremel.

downpipe: Buy a nice 10mm wrench. Cut it in half. Remove fans anytime you want to get it off. Protect radiator fins.

manifold: Buy gs-t 8mm manifold studs and nuts. Use blue loctite on the head side. drink beer.

thats weird, am i the only one that has not had a problem with the manifold studs! they're nice and tight! i still cant get that damn third bold on the dp......can someone help

Originally posted by 96rs-t
thats weird, am i the only one that has not had a problem with the manifold studs! they're nice and tight! i still cant get that damn third bold on the dp......can someone help

take a dremel to the top of the nut and shave it down some.