DC Sports uppipe?

Post by **complacent** » Tue Apr 25, 2006 12:52 pm

no worries, you won't be able to separate the UP from the exhaust manifold until you get the O2 sensor out of the way... it is blocking access to one of the two studs/nuts at that junction.

GeneralGrievous · Post by **GeneralGrievous** » Tue Apr 25, 2006 12:52 pm

I did see a DIY elsewhere suggesting unplugging the O2 from its socket up top & threading it down and out of the engine area instead of removing it. Will that work if no socket can be located?

GeneralGrievous · Post by **GeneralGrievous** » Tue Apr 25, 2006 12:53 pm

Nevermind

Post by **Sabre** » Tue Apr 25, 2006 1:23 pm

bluscooby23 wrote:it is not easy to stuff a big tool like that into such a cramped area.

Man, if I had a dollar for every time I thought that... To the quotes section!

I usually just disconnect the O2 sensor and then hang it off the lower subframe

Just be careful that you don't hit it too hard. The wire to the O2 is double zip-tied to a little braket about half way up, so removing it is a pain, that's why I just hang it over the edge

The O2 sensor is in the exhaust manifold (aka, the headers) and the EGT is in the uppipe. Pretty cool that your new UP came with a EGT sensor in it!

Just a warning, you might have to bend the stock EGT sensor a little to get the UP out.

GeneralGrievous · Post by **GeneralGrievous** » Tue Apr 25, 2006 2:30 pm

again gracias...

Got a O2 remover that's offset so clearance wasnt a problem with the wheel still on, but I did remove the airbox and then the little PITA bracket that holds the O2 wiring and took the whole sensor/wire shindig out. Wire kept coiling up as I unscrewed the sensor so proceeded as mentioned above.

Manifold coming off slowly (more PB). Will continue to update as the day progresses, again nice weather.

Hoping the wife isnt steamed about losing the driveway and me using all the ziplock bags in the house for holding/labeling bolts

Post by **Sabre** » Tue Apr 25, 2006 2:36 pm

lol, after about your 2-3rd install, you'll realize that Subaru's are put together by the following:
- 10, 12 and 14mm nuts and bolts
- Evil Subaru tech's who sharpen the edges of heat sheilds (I was warned by Colin and Zak, so I am passing it along...)

After awhile, you just pile the parts up on the windshield while taking the car appart and then just put the ones that fit back in...

GeneralGrievous · Post by **GeneralGrievous** » Tue Apr 25, 2006 3:59 pm

Well day 2 of the Batan Uppipe Death March is over (gotta clean up for dinner reservations) and I continue to have more questions.

I've as yet been unable to remove the exhaust manifold. I've got it totally unbolted and its completely mobile save for the heat shield thing on top of it. I can't fit it out past the crosspipe below it, and cant reach the bolts above it (so far) to remove the shield. Do I have to remove the crosspipe as well?

Still dreading the actual detachment of the UP from the turbo (busted knuckles here I come). After work tomorrow more work do I see... hhhmm, do or do not; there is no "try"

Post by **Sabre** » Tue Apr 25, 2006 4:43 pm

GeneralGrievous wrote: I've as yet been unable to remove the exhaust manifold. I've got it totally unbolted and its completely mobile save for the heat shield thing on top of it. I can't fit it out past the crosspipe below it, and cant reach the bolts above it (so far) to remove the shield. Do I have to remove the crosspipe as well?

Still dreading the actual detachment of the UP from the turbo (busted knuckles here I come). After work tomorrow more work do I see... hhhmm, do or do not; there is no "try"

Explain cross pipe... Do you mean the headers (the exhaust part that is attached to the engine?). Yes, you'll have to remove these (there are 6 bolts plus two bolts on the header->UP). You should be able to get enough of the shielding off that you can get to it.

If you need help with it tomorrow, I can stop by after work to help out

GeneralGrievous · Post by **GeneralGrievous** » Tue Apr 25, 2006 5:00 pm

Yeah I guess its the headers. The pipe that runs from the driver side to the passenger's side and into the manifold.

Oooo, tempting to beg a visit. We'll see about when I can get outta work I'm sure I wouldnt be home till after 4 at the earliest. And here I was trying to soldier on and not bug you guys.. except for the incessant posting that is

sirwilliam · Post by **sirwilliam** » Tue Apr 25, 2006 5:02 pm

sabre wrote: - Evil Subaru tech's who sharpen the edges of heat sheilds (I was warned by Colin and Zak, so I am passing it along...)

Or "Good" Will who custom cuts his stock FXT heat shield to fit his Helix DP...he uses a dremel to cut and sharpen into a scalpel

Nothing better than donating blood for your suby

Post by **Sabre** » Tue Apr 25, 2006 5:24 pm

GeneralGrievous wrote:Yeah I guess its the headers. The pipe that runs from the driver side to the passenger's side and into the manifold.

Oooo, tempting to beg a visit. We'll see about when I can get outta work I'm sure I wouldnt be home till after 4 at the earliest. And here I was trying to soldier on and not bug you guys.. except for the incessant posting that is

Besides a big turbo swap, the UP is one of the harder mods to do, so don't feel bad asking for help!

GeneralGrievous · Post by **GeneralGrievous** » Tue Apr 25, 2006 5:31 pm

It seems until yesterday my car felt my hemoglobin donation quota had not been reached.

Thanks for the encouraging words

GeneralGrievous · Post by **GeneralGrievous** » Wed Apr 26, 2006 6:57 pm

Quick update (I'm sure you were trembling with anticipation..NOT)..

Header/crosspipe thing off, exhaust manifold off, all bolts on turbo/DP loose except one, 2 of 3 visible bolts loose on turbo/UP, EGT sensor unplugged and ready to come out with UP.

The question is what am I missing (besides common sense that is

)?

Thanks

GeneralGrievous · Post by **GeneralGrievous** » Thu Apr 27, 2006 10:12 pm

Ok... I may have to throw in the towel here.

I have all bolts finger loose except the two from UP to turbo (cant see them) because of course the DP is in the way. Here's the problem bolts: 1 of 2 bolts on DP to Midpipe is out, the other has no "head" on it (is this normal?), I swear I didnt break it off. It was like that when I got under there. And then the one bolt for the DP bracket attached to the body/engine. Other than that everything else is ready to go. I'd hate to have to put everything back together and call it quits over two lousy bolts. Any suggestions ? Not sure who lives closest to me, I'd come to you but obviously that's not possible. My house is 1 mile from the George Mason Campus. If you'd like feel free to call my cell 703-946-7767 if that's easier than typing (what am I saying, y'all are all IT peeps). Tomorrow (Friday) or Sunday both after 4pm are open for me but Saturday I'm working open to close (like 9am-11pm). Thanks again, I have plenty of Guiness and other beers if you're thirsty

Post by **Sabre** » Fri Apr 28, 2006 10:28 am

I can be there on Sunday to help ya out

PM me your address and I'll be there at 4!

BTW, that's just a normal bolt, so one side should have a head. I'll check it out when I get there. I'll also bring the drill in case I need to drill it out!

GeneralGrievous · Post by **GeneralGrievous** » Fri Apr 28, 2006 11:46 am

PM sent... many thanks!!

And YOU DA MAN!! (grovel grovel)

Mr Kleen · Post by **Mr Kleen** » Fri Apr 28, 2006 12:09 pm

I'll see how my weekend goes and try to make it out there with the Prez on Sunday afternoon.

GeneralGrievous · Post by **GeneralGrievous** » Fri Apr 28, 2006 1:25 pm

Very cool!!

I guess I should get busy burning those 16 Horsepower CD's as for your goodie bags

You guys like chocolate?

Post by **Sabre** » Fri Apr 28, 2006 2:04 pm

Does a person breath? I mean, yes...

GeneralGrievous · Post by **GeneralGrievous** » Fri Apr 28, 2006 7:17 pm

Hey say no more... might as well do something I KNOW how to do.

GeneralGrievous · Post by **GeneralGrievous** » Mon May 01, 2006 1:10 am

Incredibly huge thanks to

Julian and

Zak for spending their Sunday night finishing my somwhat botched UP install. Who knew it would require a hacksaw and some very creative recycling of an EGT sensor? Now I definately have to buy a set of wrenches so I can have my very own Super Voltron breaker bar. Hope the chocolates were good and the CD as well. Lemme know whenever you guys wanna come for dinner at Colvin.

Super ginormous thanks..

(now let the spooling commence)

Mr Kleen · Post by **Mr Kleen** » Mon May 01, 2006 7:07 am

sorry I couldn't make it. glad things worked out and enjoy the UP.

Post by **Sabre** » Mon May 01, 2006 8:39 am

No problem Dave

I tell you, when I saw that weld on the EGT bolt, I knew this was a normal UP install. I don't think that I have ever had one go without some kind of trouble. Zak was able to save the day with his thought of cutting the bung down a little! He's always coming up with ingenious ways to get the install done!

Thanks again for the chocolates! I didn't try them last night since I ended up going over to Suzie's and forgetting them in the kitchen

I'll definitely be enjoying them tonight and tomorrow!

BTW, I've listened to about 1/2 the songs on the CD. Pretty good stuff, I'm going to try to find a studio recording to see what they sound like on there. The first thing that I noticed is the way they use the harmonica.

Suzie and I might be coming to Colvin on Tuesday

hotsam · Post by **hotsam** » Mon May 01, 2006 8:41 am

What exactly was the problem?

Post by **Sabre** » Mon May 01, 2006 8:44 am

The bung on the new (used) uppipe had an EGT in it, which was great... but it was loose in the bung. The problem is, whoever had the UP before welded the retaining nut in place, so we couldn't tighten it

Zak came up with the idea of cutting the bung down and getting the EGT out. We cutoff maybe 1/8 of an inch off the bung, pulling out the old EGT and then taking the EGT from the stock UP and putting that in there. Luckly, there was enough threads left (about 4-5) that we were able to wrench down on it enough for a good seal.