HOW TO: Change your O2 Housing AND 10.5 Housing

[trinydex]

http://forums.evolutionm.net/showthread.php?t=132695&highlight=superhatch+10.5



Interested in installing a 10.5 Hotside? Not a big fan of having to pull your turbo? Read up!

So I decided to install a 10.5 Hotside and a Megan Racing O2 Housing before getting dyno tuned again. Here's what I bought and what you'll need to do the install. You'll need everything here minus the O2 to install a hotside if you want to retain your stock O2.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_04aa2ee4.jpg

The first thing you'll have to do is remove the stock undertray, and downpipe. These are simple tasks to I didn't take pictures. Once you've got those parts out you'll look up at the stock turbo outlet and see this...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_88aecacd.jpg

^ Remove the black bracket holding the O2 housing to the Block. You're done under the car for now.

Next remove the manifold heatshield...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_bb8d275c.jpg

Then the O2 Sensor and the lower heatshield...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_3e26b925.jpg

You'll have to disconnect the O2 sensor under the coil pack cover...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_f0d6d487.jpg

You'll need to pull this clip to remove the wastegate actuator arm from the Turbine Housing...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_57183e25.jpg

Voila!

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_b0732fa8.jpg

Then you'll need to remove the manifold. Once you have everything unbolted, it will take some convincing to get the manifold out. But trust me, it can be done, as seen below....

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_6b4854e6.jpg

Once the clamp is off, slide the turbine housing and O2 housing off together, and be VERY careful not to damage the turbine blades.
You'll then need to remove the v-band clamp holding the hotside to the turbo's center section. Depending on the orientation of the clamp your's might not be as easy to get to as this...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_a39fd8c7.jpg

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_5f6c6f06.jpg

This is what it looks like with the turbine housing out, the turbo is held securely in place by the coolant and oil hardlines...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_d92303c6.jpg

This is your friend, use it on EVERYTHING you put back together!!

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_d35b07cc.jpg

You'll need to attach the O2 housing to the Turbine housing before putting it in the car. You will need to use NEW STUDS where they were on the original hotside. The hotsides do not come with them and even if you are able to get them out of your stock hotside, chances are the threads will be destroyed. So do yourself a favor, order them ahead of time and have new ones ready.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_869cfb82.jpg

Installation is reverse of disassembly. Total install time... 4 hours for me. Hope this gives some of you DIYer's some confidence to tackle this. Good Luck!!

- Steve

EDIT: Here are the torque specs...

http://www.socalevo.net/gallery/albums/userpics/10991/normal_exhaust.jpg

[trinydex]

There are a few ways to do this. If you are set on NOT removing the manifold you can split the turbo in half on the car by removing the hotside with the 02 housing attached and then do the 02 housing on a bench. I was going to do this but I decided to take the manifold off instead.

Tools needed:
12mm socket & open wrench
14mm socket & open wrench (It’s nice if you have a ratcheting 14mm wrench also)
17mm socket & open wrench
22mm open wrench (02 Sensor)
Different size extensions
Swivel sockets or a universal
Philips head screw driver
Breaker Bar
Drop light
Telescopic Magnet really helps to not lose the washers during the manifold removal
WD40, PB Blaster, Liquid Wrench…Pick one

Remove the plastic undertray first. These little screw clips can be a real pain in the a**. A philips head screw driver with a dexterity works, but a screw gun works better.

Downpipe Removal:
If you have an extra jack stand, set it up under the catback section so its not just hanging after you remove the downpipe. Disconnect the DP from your cat/testpipe and remove the two 12mm screws from the exhaust hangers holding it up. Now disconnect the two 17mm spring bolts connecting the downpipe to the 02 housing. The down pipe will be free now being held up by the two lower arm bars. Tale off the lower arm bars and remove the downpipe. Before you proceed, make sure you remove the bracket holding the factory 02 Housing to the motor.

Remove the flex section of the lower intercooler hose. This will allow you a little more room to work. I also removed the inlet pipe off the turbo. Just be carefull when putting it back together. The one screw is a little tough to get started. You don’t want to cross thread it
http://www.socalevo.net/gallery/albums/userpics/10991/normal_HOW%20TO%20Change%20your%20O2%20Housing%20A ND%2010.5%20Housing%20MErge15.jpg
http://www.socalevo.net/gallery/albums/userpics/10991/normal_HOW%20TO%20Change%20your%20O2%20Housing%20A ND%2010.5%20Housing%20MErge16.jpg
http://www.socalevo.net/gallery/albums/userpics/10991/normal_HOW%20TO%20Change%20your%20O2%20Housing%20A ND%2010.5%20Housing%20MErge17.jpg

Manifold Removal:
Make sure you soak these nuts and bolts. Remove the heat shield. Remove the 9 nuts holding the manifold to the head. (the 2 outers are 14mm, the 7 inners are 12mm) Remove the 2 nuts and 2 studs (14mm) from the manifold to the turbo. Now your downpipe is off and the manifold is disconnected from the head. Now push down on the turbo a little bit and wiggle the manifold off.
http://www.socalevo.net/gallery/albums/userpics/10991/normal_HOW%20TO%20Change%20your%20O2%20Housing%20A ND%2010.5%20Housing%20MErge18.jpg
http://www.socalevo.net/gallery/albums/userpics/10991/normal_HOW%20TO%20Change%20your%20O2%20Housing%20A ND%2010.5%20Housing%20MErge19.jpg

02 Housing Removal: Now that you have more room to work. Take out your 02 sensor from the 02 Housing. Remove the lower heat shield. The top three studs you can get from the top pretty easily. The bottom two are nuts though. You will have to get to these from under the car.
Now go ahead and reinstall in the reverse order. Be careful when putting the inlet pipe back on the turbo. Mine wasn’t on tight enough and produced a huge boost leak. Try to tighten each side equally to avoid boost leaks.

from: http://www.evolutionm.net/forums/showthread.php?t=239047