930 Crossver pipe removal

[TurboBert]

What's the best way to remove the crossover pipe that connects to the heat exchangers, turbo, and wastegate?

The nuts are pretty much welded on with rust but I've had good luck so far removing some of them. I've removed the bolts connecting the pipe to the heat exhangers using a lot of heat and WD-40 but I can't get the heat onto the turbo bolts. I don't want to risk rounding the nuts so I'm thinking it would be easier to take the whole exhaust out.

Is it possible to take the entire exhaust out with Turbo and wastegate attached without lowering the engine and removing the rear bumper? Other than removing the heat exchanger nuts and muffler strap, what other bolts do I need to take off to get the exhaust system out?

[jbailey930]

Bert
You can take the entire exhaust off without dropping the engine or removing the bumper. Although its not too difficult to remove your bumper. The rocker trim, license plate lights and then the major 4 bolts of the bumper are that is it.

Anyway drop the exhaust make sure you soak those head nuts thoroughly. If you have access to air tools, you may have to use a die grinder to cut off the bolts that are frozen. I've been re-building my turbo motor and recently sold off the exhaust. To separate the cross over, I was able to remove all but one bolt. That last one had to be cut with the grinder as I indicated. All that heat down there along with rain, dirt, gunk, etc. Good luck
You can do it.

[TurboBert]

For the record, I was able to finally get the crossover pipe off. The steps were:
1. Remove the bolts to the heat exchangers and the wastegate.
2. Remove the rear bumper.
3. Remove the muffler. This allows enough room to put heat on all 4 nuts securing the Turbo intake flange.
4. Remove the bolts from the turbo intake flange. The 2 forward bolts are connected with a bracket to keep the bolts from turning - which is real helpful since it's hard to get a wrench on at least one of these nuts (forward driver's side). It's definitely a good idea to invest in ratchet wrenches before you start becuase the clearance are tight.
5. Wiggle the pipe off and hold the wastegate in place with some bungee cord.

To answer my original questions:
"Is it possible to take the entire exhaust out with Turbo and wastegate attached without lowering the engine and removing the rear bumper? "
Yes and No. You can easily remove the system without lowering the engine but you'll probably need to remove the bumper to get at the rusted nuts. After that, it will be easier to remove the muffler to get at the 3 nuts that secure the Turbo bracket. Once these 3 nuts are loose and the muffler's off, remove the crossover pipe bolts connected to the heat exchangers. After that, just remove the oil lines and you are good to go.

"Other than removing the heat exchanger nuts and muffler strap, what other bolts do I need to take off to get the exhaust system out?" In addition to the heat exchanger bolts and strap, you'll need to unloosen the bracket that supports the turbo housing. The bracket is attached to the turbo via the 4 studs that attach the turbo exhaust to the muffler. If you don't remove the muffler, you will need to remove the 3 nuts that retain this bracket to the back of the pulley housing.

[Jocke]

When the bumper is down there is no problem at all to take the exhaust down.

When I rebuild my exhaust and took the old one down, I remove all bolts from the turbo then its just to take the mufffler down after that I removed the nuts against the headers. Then the rest of the system came down.

Fast and easy, but not the most economical, the gaskets to the turbo arent cheap!


/J