TURBO Down PipeInstallation Instructions |
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TURBO Down PipeInstallation Instructions |
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Raise the vehicle to working height with hoist
or jack stands. Remove the two nuts at the catalytic 
converter and turbo down pipe flange. (Figure 1)
Move rearward and to the side for working clearance.
Loosen (but do not remove) the v-clamp at the turbo outlet, then shake the down pipe from below to loosen at the turbo outlet.
Remove the MAP sensor on the firewall (Figure 2)
to create sufficient working area for the Sawzall. Remove the transmission dipstick
and tube. To Keep debris or metal shavings 
from getting into the exposed end of the dipstick tube under
the vehicle, place a clean, large rag or wiper in the opening. (Be sure your rag
or wiper is big enough that it will not fall into the tube)
Angle the Sawzall high and to the left and cut the down pipe approximately 4 inches from the clamp which connects it to the turbo. (Figure 3) The object is to remove the "corba head" from the upper end of the down pipe so that it is possible to drop the remainder of the pipe out of the bottom of the vehicle.
Note: We suggest starting with a new blade (Milwaukee
#5187 metal cutting blade) because the factory pipe
material is tough and dulls blades rapidly.
Remove both sections of the factory pipe, then determine the path for the new US Gear "round" down pipe by inserting the top section of the new pipe into the empty channel which contained the factory down pipe. Take note of where the new pipe will cross the body seam under the vehicle.
Reverse the blade in the say (or turn the say upside
down) and, from under the vehicle, make two cuts in the body seam approximately 3#
on each side of the path where the new pipe will cross the seam. (Figure 4) Place
the "duck-bill" port-a-power at the body seam 
and transmission and
with a block of wood, fold the seam toward the rear of the vehicle as shown.
(Figure 5) This will create the necessary clearance for the new down pipe to be placed
in the path without coming into contact with the body seam.
With t he insulating material provided, wrap the top section of the new down pipe and clam the end. (Figure 6) Note: Soak the wrap in water to make the material more flexible. Remember to leave 2 to 3 inches exposed at the bottom to allow for the slip joint on the lower section.
Install the top section to the turbo outlet with
the v-clamp provided. Note: The v-clamp included with the kit is a spare in case
there is damage done to the factory clamp during removal or reinstallation. Do not
tighten at this time. Position the top edge of the 3" Torca clamp provided flush
with the top edge of pipe. The clamp must cover the slots. Finish tightening
nut to 
approximately 60 ft. lbs. (Note: If torque wrench
is not available,
tighten nut until 13-14 bolt threads are exposed beyond nut (13/16" -7/8").
This is equivalent to the diameter of a nickel. (Figure 7) Reattach the catalytic
converter to the flange, but do not tighten.
Staring at the flange, position all the components
for proper clearance and begin to tighten, working up the pipe toward the turbo.
With the down pipe in the proper position, tighten the turbo v-clamp to 50 - 70 in.
lbs. Reinstall the transmission dipstick assembly and the MAP sensor. Star the engine
and check for exhaust leaks. Power brake the vehicle in both forward and reverse
to ensure clearance, adjust if necessary (Body clearance).
| Kit includes the following parts (as shown in above figure) |
|||
| Item |
Number |
Description |
Quantity |
| 1 | DP-7301 | Top Down Pipe | 1 |
| 2 | DP-7302 | Bottom Down Pipe | 1 |
| 3 | AC-3000 | Torca Clamp | 1 |
| 4 | HW-7300 | Heat Wrap | 1 |
| 5 | HC-3000 | Hose Clamp | 1 |
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