Is it possible to replace the downpipe on my classic impreza myself? Has anyone done it themself, if so how much clearance is needed underneath?

 

easy enough job. you must remove the intercooler and give the 5 nuts on the top of the downpipe connected to the turbo a good squirt with wd 40 and leave for 24 hours before trying to remove them, if you can get the 5 nuts cracked off everything else is a piece of ****.

Jim

 

If its never been off it can be a pig of a job. Took me 8 hours, the first 4 bolts/nuts came out dead easy. After that it turned into a mare, I used the cutting gear to heat it up the nut but still no joy, just rounded off the nut. In the end I had the chisel it off and weld a nut onto the remains of the stud to get that out.

Hopefully you won't have the same probs but thought I would warn you just in case.

PS mine's a 93

 

cut and paste from my help pages on my website.. don't want to get accused of advertising so not link to it etc..

How to change the downpipe
Tools Required

Screw driver for jubilee clips or correct size socket
14mm Spanner prefereable ratchet spanner
10mm Spanner prefereable ratchet spanner
22mm Spanner for the Lambda sensor
Socket set with 14mm, 12mm, 10mm sockets and some extension bars
Trolley jack and Axle Stands or ramps
WD40 or similar release agent
Remove the Intercooler

To remove the intercooler you need to undo 3x12mm bolts,
then the jubilees on throttle body and turbo..
pull towards passenger side with a wriggle to get it off turbo.. not you the intercooler lol..
careful if you lever the pipe as it is sometimes brittle.

Remove the Turbo Heatshield

You remove the heat shield over the turbo by.. from memory.. 10mm headed bolts - 5 if I remember correctly.
Two on passenger side, one on the rear and then two right down the bottom on drivers side..
might be others
some might sheer if they have never been removed.
Make sure you give them a good spray first with release agent

Remove the Downpipe

Spray all the nuts and two bolts with release agent
Undo the two bolts in the top, then just nuts to come off studs...
outside edge ones you can get to with spanner from top,
but I find the middle one is easier with socket and extension from underneath..
jack and axle stands need to get under.

The key is a good quality spanner, Halfords professional are very good.

You then just have the two bolts to the centre section and one support bracket
where the downpipe runs back under the car and the bracket is attached to the gearbox.

Remove Lambda or Cat on Fire Sensor

Disconnect the Lambda sensor electrical plug or if you have an early 90s car then disconnect the
cat on fire sensor.

Spray Release agent on the sensor

Remove the sensor

Fit the new downpipe

I attach downpipe to turbo first to make sure it is done up flush You might want to get a new gasket to save doing it again when it leaks..

although mine has been on and off a few times on the same gasket.
Then do up the bolt to the support bracket
which mine not longer lines up for..
probably when I dropped the gearbox when I had that out lol..
then attached to centre section obviously.

To get the intercooler on easier heat the turbo end of the pipe with hot water..
dip it in a mug full of boiling water.. it should then slide on without too much effort if you are quick..
this is assuming you still have the black plastic pipe..
if changed to samco then it should just push on without heating..
put the jubilee further up the intercooler pipe and tighten it slightly before hand then you can undo it
and move it down once on the turbo.. then do the throttle body connection which is fiddly
I find it easiest to fit the intercooler without this pipe and then squash the pipe through the gap and on
and then fit the jubilee clips afterwards having openned them out fully to get them over the pipe etc..

ReFit the Heatshield

You will need to cut the heat shield as the new downpipe will be fatter..
The fit and replace the 10mm bolts.
ENJOY!
Don't be surprised if all the release agents smokes for a while.

I hold no resposibility for any damage you do!

© 2006 JollyGreenMonster.co.uk, all right reserved.

 

Just what I needed JGM, thankyou very much once again.

 

no problem..

Simon

 

Top guide Simon