Fast Intentions Downpipe 6MT Installation Tips

[Bpitz15]

Since I had my camera out while installing my downpipes I figured I would take some pics of some of the difficulties of the install and how I dealt with them

To Start-
Disconnect the two 02 sensors from the firewall in the engine bay.
The Passenger side (upper) O2 Sensor is located here:



Second on the left. Just pull that out and disconnect it so it can be pulled out with the DP.

Now the driver side O2 sensor is a bit more complicated...
-Remove the coolant reservoir by removing the phillips head screw on top of reservoir. here is is already unscrewed on bottom right of pic


-Pull up and out towards you to remove the reservoir. Disconnect sensor on bottom and move to the side out of your range of work.


Exposing this


down behind the engine there is a fabric piece of heat shield. It has two snaps and is wrapped around about 4 different wires.
Undo these snaps and remove fabric. Now locate the d.side O2 sensor wire. It looks similar to the pass. side O2 sensor. It has five wires wrapped in a sort of black conduit.
Unplug this and let it dangle.

[Bpitz15]

Now get under your car. Preferably on all fours like so


Disconnect cat-back by removing whichever kind of exhaust clamps you may have. And remove exhaust from the 4 hangers in place (middle and rear).
Now start removing the Axel half-shaft heat shield up front.
On-


and Off-


There are 3 Allen Key bolts on each shield. Removing these will open up LOTS of space in the working area.

[Bpitz15]

Remove the lower O2 sensors whenever you get a chance before removal of exhaust. Mark one with tape in order to remember which side they go on.

Next go at the manifold bolts.
This is where the real fun begins.

For the lower bolts on each side I used a stubby ratchet w. a small extension and 13mm socket.


I was told to use a 2ft. long 3/8ths extension to reach some of the bolts but I made due with this setup if you don't have the resources.

[ngng]

i used two long extensions connected by an movable/angle adapter...passed the extension over the axle, from the back. i didn't remove the heat shield either.

[Bpitz15]

Once all bolts are removed from manifold. Removed the brackets on the transmission that are connected to the DP. Now that the downpipes are free of catback, slide the downpipe out (Upper O2 sensor still connected). While they are out you can remove the upper O2 sensors and put them into the corresponding new downpipe.

Here is a little trick I came up with to help me get the O2 sensor on the new DP up back into the plug location.



I cut a length of string and tied it up to a solid object in the engine bay. I than dangled the string in the original path that the upper O2 sensor once took.

This will allow me to tie the bottom of the string to the O2 sensor plug and pull it up through the engine bay while the new DP is in place.

Now Install the new DP's in the opposite order of the stock ones. Make sure the floating flanges are matched up and tighten up the manifold to DP bolts. Put the bracket back on. And connect the new DP to the existing or new cat-back.

Place all heat shields back on, and place the plastic skid plates back on as well.


TA-DAHHHHH
http://www.youtube.com/watch?v=1RSVdQNttcs

Any questions or comments let me know!

Thanks to all for the help and I hope this helps speed up the process for the future DIYers


-Brandon

[Stormin]

Damn...

Nice Write Up.

[Justincredible]

Addition for those of you who have a tiptronic.

1 you don't have the same room as the 6 speed and you will need to remove the 02's from up top. I suggest using a crows foot. Pull the connector brackets off of the fire wall to gain more axsess to the 02's once that is done it is quite easy to get to

2 also the automatic trans is bigger so the Dp's wont fit past the trans and the trans mounts with out lowering the motor cradle in the back

[Bpitz15]

I have to bring this back from the dead,

Today I got back under my car since i heard an exhaust leak,

1. The exhaust has always stuck out past the bumper to my liking so i chopped some material off and brought them much closer to the bumper and centered them a bit more in the cutouts. Came out great.

2. The exhaust clamps werent sealing to my liking so I sprayed them down w/ PB blaster and cranked them down.

3. A bolt that connected the 2-pieces of the DP rattled out! Put a new one on that and added lock washers to all 4 bolts.

4. I got to my Manifold connection and had to re-tighten the 3 nuts on each side and about 50% of them had to be re-tightened. A MUST DO for anyone who hasnt been under there car since the install.

[Bpitz15]

http://www.youtube.com/watch?v=6guftlV4Ti8
catback rev

http://www.youtube.com/watch?v=Uu7lsjj2Al0
full back rev

i did not dyno the car but I absolutely felt a difference in Hp/Tq. I dont exactly know how much i gained since my butt dyno isnt too calibrated but it is noticeable.
I belive my catback is resonated.

you can search the rest of my vids on youtube for a couple drive-bys and such

[ngng]

wow man, i forgot this was your car. your new wheels are so much better than the oldies :P

another point that should be stressed...mark those O2 sensors...you don't think it'll happen, but I know lots of guys who have mixed up the banks

[Bpitz15]

wow man, i forgot this was your car. your new wheels are so much better than the oldies :P

another point that should be stressed...mark those O2 sensors...you don't think it'll happen, but I know lots of guys who have mixed up the banks

hahaha you wait till i get my spacers and coils, you will eventually like it

and yes that is a good point. i put tape around one and put tape on the underbody in relation to that o2

btw i did my repairs on a lift and holy crap this install could have taken 2 hours. If you have access to a lift..take it!!

[joeycuccaro]

hahaha you wait till i get my spacers and coils, you will eventually like it

and yes that is a good point. i put tape around one and put tape on the underbody in relation to that o2

btw i did my repairs on a lift and holy crap this install could have taken 2 hours. If you have access to a lift..take it!!

Any CEL issues?

[Bpitz15]

Any CEL issues?

actually yes... i had my codes cleared and when i went in for my 45k service the dealership cleared codes again and the CEL is back on... which leads me to ask for help from you guys...

i have 2 vast O2 sims and i cannot run two at the same time since the bungs in my DP point right at each other.. what I want to do is run one vast O2 sim and one of those 90 degree angle O2 sims... what i need from the zine is help locating one of those 90 degree angle O2 sims....

anyone??

[joeycuccaro]

actually yes... i had my codes cleared and when i went in for my 45k service the dealership cleared codes again and the CEL is back on... which leads me to ask for help from you guys...

i have 2 vast O2 sims and i cannot run two at the same time since the bungs in my DP point right at each other.. what I want to do is run one vast O2 sim and one of those 90 degree angle O2 sims... what i need from the zine is help locating one of those 90 degree angle O2 sims....

anyone??

Good info, Im going to get the spacers just incase when i get my DPs back. I will ask my mechanic tomorrow where you can get a 90 degree one.

Thanks again for the write up, i just took out my DPs today in about 2 hours. Only PITA was the top allen bolts for the axle shields and loosening (not breaking) the top two bolts off the manifold.

[Bpitz15]

Good info, Im going to get the spacers just incase when i get my DPs back. I will ask my mechanic tomorrow where you can get a 90 degree one.

Thanks again for the write up, i just took out my DPs today in about 2 hours. Only PITA was the top allen bolts for the axle shields and loosening (not breaking) the top two bolts off the manifold.

your welcome!! and thanks for asking your mechanic!!

those bolts proved to be the biggest bitch for me too.. glad its over with.. now onto the next project

[joeycuccaro]

Hey man!

Checked with my mechanic today and it seems they do not offer 90 degree spacers. Are the O2 sensor holes facing one another with the aftermarket down pipes?

Also, do you have the torque specs for all of the downpipe bolts (manifold bolts and tranny mount bolt)

Thanks a lot!

[Bpitz15]

Hey man!

Checked with my mechanic today and it seems they do not offer 90 degree spacers. Are the O2 sensor holes facing one another with the aftermarket down pipes?

Also, do you have the torque specs for all of the downpipe bolts (manifold bolts and tranny mount bolt)

Thanks a lot!

hey thanks for checkin in with the mechanic.

In my absolute last pic you can see my lower o2 sensors facing directly at each other. The VAST o2 sims that i picked up extended these bungs towards each other. which only allows me to use one o2 sim instead of both given the size of the o2 sensor itself + the bung. Which is where i need the 90 degree sims.

As for the torque specs, i dont have any. What I did was tighten them as much as possible. Than a month or two later i got back under the car and re tightened them as much as possible. I dont think a little thread lock would hurt.

any other readers.. please let me know if you know of any body that sells the 90 degree sims.

Hows your car coming along??

[joeycuccaro]

hey thanks for checkin in with the mechanic.

In my absolute last pic you can see my lower o2 sensors facing directly at each other. The VAST o2 sims that i picked up extended these bungs towards each other. which only allows me to use one o2 sim instead of both given the size of the o2 sensor itself + the bung. Which is where i need the 90 degree sims.

As for the torque specs, i dont have any. What I did was tighten them as much as possible. Than a month or two later i got back under the car and re tightened them as much as possible. I dont think a little thread lock would hurt.

any other readers.. please let me know if you know of any body that sells the 90 degree sims.

Hows your car coming along??

Its going pretty good. Whole front end is back on, just waiting to finish up the downpipes tomorrow. They are mounted im just going to look for some torque specs. I think im also going to sand the x-pipe and pre muffler down and they high temp paint it. The finish is kind of wearing and i dont want any rust on it.

BTW i never caught your name...? Im sure you can guess mine, haha.

[whartung]

random related aside.

I'm considering doing the Vast piggies. I just want to know how hard you think removing the downpipes is. I'm pretty mechanically inclined, but I'm for the most part just kinda starting my DIY phase. What do you think?

[joeycuccaro]

random related aside.

I'm considering doing the Vast piggies. I just want to know how hard you think removing the downpipes is. I'm pretty mechanically inclined, but I'm for the most part just kinda starting my DIY phase. What do you think?

Its not that bad. If you could install your cat-back then i dont think you would have a problem.

Since you have the 6-speed its easier because there is more room.

As stated above take the top O2 sensor plugs out first then get under the car.

First you remove the axle shields. 3 allen bolts on each side and remove.

Next unbreak the 6 13mm bolts on each manifold (3 on each side). Its relatively simple with a 2 foot extension and a swivel socket.

After they are loose remove the 16mm bolts on each down pipe where its bolted up to the tranny. Disconnect the rear O2 sensors and twist the down pipe out.

Your done!

[nimski62]

Is there any way to change front o2 sensors without removing the dps?

[Bpitz15]

Its going pretty good. Whole front end is back on, just waiting to finish up the downpipes tomorrow. They are mounted im just going to look for some torque specs. I think im also going to sand the x-pipe and pre muffler down and they high temp paint it. The finish is kind of wearing and i dont want any rust on it.

BTW i never caught your name...? Im sure you can guess mine, haha.

the names Brandon

sounds like your gonna have a completely different car after everything is buttoned up! Congrats!!


Whartung- i am not new to cars and I have a lot of knowledge from reading but now that I am out of college and have a full time job ... and $$... I am now able to afford aftermarket parts and actually mod my cars, and I would say my DP's were the biggest project i've ever tackled. I have also done my snub, and short shifter. So for comparison, the DP's were the most difficult.

If you have access to a lift TAKE IT!! the second time i got under my car i got to use a dealerships lift by myself and i had to right tools at hand and holy crap was it easy. The jackstand method was a bit difficult but I took my time and got it done in about 8 hours over two days. Knowing what I do now.. I could do it in 3.
People do recommend the long extensions and after using one the second time around, I do too.

You will need two people at times when lowering and raising the cat-back. But i did do the whole project myself. GOOD LUCK

any q's pm me or pm me for my cell #. Also Danny at fast intentions is very knowledgeable and helped me w/ a couple phone calls.

[whartung]

the names Brandon

sounds like your gonna have a completely different car after everything is buttoned up! Congrats!!


Whartung- i am not new to cars and I have a lot of knowledge from reading but now that I am out of college and have a full time job ... and $$... I am now able to afford aftermarket parts and actually mod my cars, and I would say my DP's were the biggest project i've ever tackled. I have also done my snub, and short shifter. So for comparison, the DP's were the most difficult.

If you have access to a lift TAKE IT!! the second time i got under my car i got to use a dealerships lift by myself and i had to right tools at hand and holy crap was it easy. The jackstand method was a bit difficult but I took my time and got it done in about 8 hours over two days. Knowing what I do now.. I could do it in 3.
People do recommend the long extensions and after using one the second time around, I do too.

You will need two people at times when lowering and raising the cat-back. But i did do the whole project myself. GOOD LUCK

any q's pm me or pm me for my cell #. Also Danny at fast intentions is very knowledgeable and helped me w/ a couple phone calls.

great to know. thanks for being so helpful.

How did you get to use the dealership lift?

I'll probably be stuck on the floor doing the jackstand method. If i do it, it will probably be in the spring. And i'll probably have to do it in one day. I'm good at this sort of thing though, so I'm not too worried if you say that it CAN be done in just a few hours.

I've done a short shifter and a snub. Those weren't hard, so I hope this one goes smoothly too.

[Bpitz15]

great to know. thanks for being so helpful.

How did you get to use the dealership lift?

I'll probably be stuck on the floor doing the jackstand method. If i do it, it will probably be in the spring. And i'll probably have to do it in one day. I'm good at this sort of thing though, so I'm not too worried if you say that it CAN be done in just a few hours.

I've done a short shifter and a snub. Those weren't hard, so I hope this one goes smoothly too.

my father is a parts manager at a dodge dealership and i got to use it after hours.

But yeah if you have all the exhaust clamps, extensions, tools, etc... ready you will be all set. Preparation is key, dont wanna make any parts runs.

Remember to take those axle shields off, get that car up in the air as high as possible and have some fun!!

also to you and joey, dont be afraid to trim some length off the DP's if the tips stick out too far. I had to trim mine twice to get it to look good, not great.

[whartung]

my father is a parts manager at a dodge dealership and i got to use it after hours.

But yeah if you have all the exhaust clamps, extensions, tools, etc... ready you will be all set. Preparation is key, dont wanna make any parts runs.

Remember to take those axle shields off, get that car up in the air as high as possible and have some fun!!

also to you and joey, dont be afraid to trim some length off the DP's if the tips stick out too far. I had to trim mine twice to get it to look good, not great.

well if i did it i'd be getting the stock ones piggied, so I dont think trimming will be an issue for me.

[joeycuccaro]

well if i did it i'd be getting the stock ones piggied, so I dont think trimming will be an issue for me.

Yeah i have piggies, i didnt go aftermarket.

FYI when you get your pre-cat gutted, make sure the mechanic knows that the PRE-CAT is actually the cat farther down the downpipe.

The main cat is the one closest to the manifold.

[S-Fore]

Looks good, a bit of advice though, go to:

www.verociousmotorsports.com

and get yourself a pair of SS band clamps. They will start to leak as the system heats up and shifts over time. I threw a SS sleeve and wrapped that in a band clamp for my set-up. I just went through it, so i thought I would throw it out there.

[V8EURO]

I'll be installing a set a VAST down pipes on my car monday, with the help of a buddy and his lift. Any other helpful hints post em up please

[37doc]

seems like a lot of work for the upper o2 sensors, I just bought the sensor tool and removed them from the DP's with the connectors still installed? worked like a champ .

[37doc]

"Next unbreak the 6 13mm bolts on each manifold (3 on each side). Its relatively simple with a 2 foot extension and a swivel socket. "

I didnt use much extension at all , I just stuck my arm uo in the DP tunnel got the straight socket on and removed the nuts.

Also when you remove the O2 sensors, you will have to twist the leads up when unscrewing them from the DP's just remeber approximately how many times you rotate them counter clockwise and twist them CCW the same amount before reinstalling them into the DP's so your leads wont be twisted up in the normal position.

[joeycuccaro]

"Next unbreak the 6 13mm bolts on each manifold (3 on each side). Its relatively simple with a 2 foot extension and a swivel socket. "

I didnt use much extension at all , I just stuck my arm uo in the DP tunnel got the straight socket on and removed the nuts.

Also when you remove the O2 sensors, you will have to twist the leads up when unscrewing them from the DP's just remeber approximately how many times you rotate them counter clockwise and twist them CCW the same amount before reinstalling them into the DP's so your leads wont be twisted up in the normal position.

Yeah i could of probably got away without using a an extension but i found it to be a little easier.

[Bpitz15]

Yeah i could of probably got away without using a an extension but i found it to be a little easier.

and there is no need for an o2 sensor removal tool if you dont have one just unplug them from the firewall like i did and slide them out while still attached to the stock DP.

i used a shorty and an extension two different times and i found the extension easier as well.

[nimski62]

and there is no need for an o2 sensor removal tool if you dont have one just unplug them from the firewall like i did and slide them out while still attached to the stock DP.

i used a shorty and an extension two different times and i found the extension easier as well.

Okay, my front o2s need replaced. When I looked under the car, I couldnt see anywhere where I could, but is there any way to remove the front o2s with the stock DPS still in the car? If so how hard is it?

[37doc]

Yes you can get the front o2 sensors from underneath, a lift is very helpful, and yes it is tight, but not all that terrible.

[37doc]

"and there is no need for an o2 sensor removal tool if you dont have one just unplug them from the firewall like i did and slide them out while still attached to the stock DP."

Yes I understand this , however youre missing my point , which is you dont have to fiddle with all of that crap topside if you buy the crowsfoot! big time saver....

[Bpitz15]

"and there is no need for an o2 sensor removal tool if you dont have one just unplug them from the firewall like i did and slide them out while still attached to the stock DP."

Yes I understand this , however youre missing my point , which is you dont have to fiddle with all of that crap topside if you buy the crowsfoot! big time saver....

copy that! but i dont want the DIYers that read this to think they need to go out and buy one. Just trying to keep this thread as informative as possible.

[joeycuccaro]

copy that! but i dont want the DIYers that read this to think they need to go out and buy one. Just trying to keep this thread as informative as possible.

Brandon,

Got the car finished today. Just got back in from a test drive. The thing sounds MEAN with my non-res labree. Acceleration seems a little better. the car all around feels better after i didnt all of this work (plugs, belt, snub, dps, etc).

BTW do you mind if i make an official write up with your pics? Yours is great but i think a few points need a bit more detail if anyone not mechanically handy wants to try it.

[Bpitz15]

thats cool with me man thats what this site is all about

[littleredwagen]

FYI Torque specs are for the 3 bolts for the DP to mani are 27nm, and the support bolt is 25nm.

[V8EURO]

Took the car in today for 35k service, JHM shifter install, & DP install. Hoping it was going to all go smooth and take no more then 3 hours. well 4 hours later we figured out the down pipes were not going to fit, the pipe that meets the manifold at the top was off by about a half inch on the passengers side and a little on the drivers side. when you lay them next to the stock ones you can see the angle is off, have to send them back. during this we noticed a large amount of oil on the belly pan and all around. I'm thinking its the valve seals. we put some dye in so time will tell. Never got around to the shifter. all said and done 4.5 hours of labor and all i got was an oil change. not so nice monday.