Perrin Subaru Performance Up-pipe Installation
WARNING!!
THESE INSTRUCTIONS ARE FOR THE PERRIN UP-PIPE ONLY!
PEOPLE USING THESE INSTRUCTIONS FOR AN UP-PIPE NOT DESIGNED BY PERRIN PERFORMANCE MAY ENCOUNTER INSTALLATION PROBLEMS, IMPROPER TORQUE SPECS, AND EXHAUST LEAKS.
IF YOU ARE USING ANY UP-PIPE WITH A FLANGE THICKNESS LESS THEN 1/2 INCH YOU WILL HAVE TO MODIFY THE TORQUE SPECS AND TORQUE SEQUENCE!! YOU MAY ALSO ENCOUNTER PROBLEMS WITH YOUR UP-PIPE FLANGES WARPING. PLEASE CONTACT THE UP-PIPE MANUFACTURER FOR INSTALLATION INSTRUCTIONS.
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We recommend a professional mechanic do this installation!
Please read through all the instructions before performing the installation
THIS PART IS FOR OFF ROAD USE ONLY! CONTACT YOUR LOCAL AUTHORITIES PRIOR TO INSTALLATION
Tools you will need: Oxygen sensor wrench 3/8 drive ratchet 1/2 drive ratchet, Assorted extensions for 3/8 and 1/2 drive ratchets, 10mm,12mm,14mm sockets 3/8 drive 12mm,14mm sockets in 1/2 drive 2- 14mm open-ended or gear wrenches, 10mm open-ended or gear wrenches, Flat head screwdriver, Liquid wrench or equivalent lubricant, Assorted pliers, Resistor
DISASSEMBLY
Make sure you spray all the bolts with Liquid Wrench or equivalent. Let the Liquid Wrench soak before removing factory parts. The exhaust system is exposed to high heat and pressure, nuts and bolts may seize during the removal process. Allowing the lubricant to soak insuring a trouble free installation. Allow the car to cool for several hours.
1. Remove the lower plastic splash guard to gain access to the exhaust system from under the car. (3) 10MM BOLTS AND 4 POPITS
2. Remove the air cleaner and air box for access to some of the exhaust bolts. (2) 12mm bolts down low on the chassis.
3. Start by removing the blow off valve (2) 12mm bolts then remove (2) 12mm bolts on either side of the intercooler and the hose clamps that attach the boost tubes to the turbo and intercooler.
4. Unbolt the intercooler support bracket from the passenger side of the motor. (2) 12MM BOLTS
5. Remove the heat shield from the turbo charger. The heat shield is held in place by (7) small 10MM bolts.
6. Spray down all of the turbo manifold bolts with Liquid Wrench so these bolts will be easier to remove later.
7. Remove the exhaust down pipe, and 2 midpipes. (Aftermarket exhaust could be different) (5) 14mm bolts (turbo) (1) 14mm bolt to transmission case, and assorted 12 & 14mm bolts on the 2 midpipes.
8. Be sure to support the mid pipe that contains the rear O2 Sensor.
9. Remove the lower turbo heat shield at the same time. Mounted to the factory up-pipe with (2) 10mm bolts
10. Remove the small access panel in the passenger side wheel well. This will give you access to the Oxygen sensor.
11. Use an Oxygen Sensor socket for easy removal Remove the Oxygen sensor wire bracket Remove the 12mm bolt mounted on the #3 cylinder coil This will make removal of the Oxygen sensor easier.
12. Remove the 5, 14mm nuts that bolt the turbo to the up-pipe and larger bracket. (3) for the turbo, (2) for the bracket. It may be helpful to loosen the one bolt on the larger bracket that holds the bracket to the block.
13. Remove the lower exhaust manifold heat shields. (4) 12mm bolts The exhaust manifold can now be removed. Remove the 7 bolts on the lower exhaust manifold ( 3) 14mm nuts, (4) 14mm nuts and bolts
14. Unplug the factory EGT sensor. The connector is located on the passenger side shock tower under the removable panel. (2) black wires You will now need the resistor that comes with your up-pipe. Insert the provided resistor into the female end of the plug.
15. Lift the motor Remove the passenger side motor mount nut & washer. Use a floor jack and block of wood to jack the engine up enough for the up-pipe to be removed out the bottom. You need to lift the engine approximately 2 inches. Be careful not to hit the EGT sensor on the way out.
16. Lower the engine and tighten the motor mount nut. The motor does not need to be raised for the installation of the new up-pipe. You can lower the engine and retighten the motor mount immediately after you have removed the factory up-pipe. Place the factory gaskets from the OEM up-pipe onto the Perrin up-pipe.
17. Slide Perrin the up-pipe into the car from the top. (This is easier than the removal, since the Perrin up pipe has more clearance.) Place Perrin up-pipe into the turbo bracket, using one of the nuts to hold it in place.
18. Important! When you reinstall the lower exhaust manifold with the old gaskets, don’t tighten all the nuts and bolts. Leave them hand tight until all bolts and nuts have been installed. (3) 14mm nuts, (4) 14mm nuts and bolts. Snug all nuts and bolts down on the manifold, up-pipe, crossover pipe, and brackets.
19. Be sure to snug up-pipe and manifold first. Install and snug the nut on the small turbo bracket (1) 14mm nut. Torque the nuts and bolts in this order: Manifold to up-pipe (2) 14mm bolts Manifold to cross over pipe (2) 14mm bolts Manifold to block (3) 14mm nuts Finally turbo to up-pipe (3) 14mm nut Small and Large turbo bracket (2) 14mm nuts
REINSTALLATION
Reinstall all parts in reverse order. Start the car to let it warm up and listen for exhaust leaks. It is normal for engine noise to come from the new Perrin up-pipe, due to the lack of a catalytic converter and heat shield.
For questions & comments please contact
Perrin Subaru Performance
info@Perrinperformance.com
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