More pics to follow.





Before install day ensure that all tools and materials are present. (NOTE: the Invidia DP that I purchased did not come with a turbo/DP gasket so make sure your DP comes with it or get one from Subaru.
Tools required: 14mm & 17mm wrenches (Differential protector)
12mm & 14mm wrenches/sockets (DP and cat-back)
10mm wrenches/sockets (heatshield)
O2 sensor socket
Various ratchet extensions


STEP 1: Put car on a lift or ramps (I backed my car up onto ramps)


STEP 2: Spray WD-40 (or similar) on all accessible bolts (exhaust and heatshield)


STEP 3: REMOVE DIFFERENTIAL PROTECTOR (if installed)
Tools required: 14mm & 17mm wrench
After completing the install and checking clearence of the exhaust, it looks like removal of the diff. protector is not required BUT the exhaust piping may be close enough to the diff. protector to make it rattle.


-Unbolt the four bolts on the sides(NOTE: driver side bolts cannot be removed with the exhaust installed.

-Loosen the two bolts at the rear. Slide wrench in-between the differential and the Diff. protector(1-2 revolutions, do NOT remove)

-The Diff. protector will now slide out of position.

-Retorque rear bolts
(I chose to re-install the four bolts on the side so I wouldn't lose them. You will need the spacers and washers to do this(NOTE: the drivers side bolts are longer))


STEP 4: REMOVING THE HEATSHIELD
Tools Required: 10mm socket/rachet(3 inch extension)

-Remove all bolts. You cannot see the ones on the driver side so you will have to feel for them. I used a 3in. extension to get at the hard to reach bolts.

-Once heatshield is removed spray WD-40 on the DP bolts.


STEP 5: REMOVE O2 SENSOR
Tools required: O2 sensor socket and rachet(02 sensor socket NOT required, you can use a....19mm if I remember correctly

-Loosen O2 sensor and remove


STEP 6: REMOVE THE EXHAUST
Tools required: 12mm & 14mm socket/ratchet and wrench.

(NOTE: I chose to seperate the exhaust at each flange so it would fit in the Invidia box. You can leave it in one piece by unbolting it at the downpipe and taking it off the hangers if you so desire.)

-Starting with the axle-back portion. Use 14mm socket and ratchet to remove the two bolts forward of the rear axle. Remove the bracket from the hanger forward of the axle(get something to set the piping on or else the muffler will hit the bottom of the bumper when you set it on the ground.)

-Remove the brackets from the hangers attached to the muffler

-Work your way forward and remove each section. The rest of the bolts are 12mm.


STEP 7: REMOVING THE DOWNPIPE
Tools required: 14mm socket/ratchet and wrench

-Remove the two bolts/nuts and three nuts from upper flange.
(NOTE: the DP will rest on the three remaining non-removed bolts)

-Remove the bolt on the lower elbow of the DP. (access from under the car)

-You can now remove the DP from under the car.


STEP 8: INSTALLING THE NEW DP
(NOTE: The factory gasket is not a perfect match for the Invidia DP so I ground the corners that did not match with a dremel.

(NOTE 2: I had to grind the lip off the nut on the lower passenger side because the bellmouth was too close to the bolt hole to install it.
-Place gasket on the upper flange and let it hang from the non-removed bolts.

-Put a piece of cardboard down on the floor. Put the DP on the cardboard to slide it under the car so it won't get scratched. Raise the bellmouth up and into position to rest on the non-removed bolts on the turbo.

-Install two bolts/nuts and three nuts (do NOT tighten) on the turbo/DP flange.

-Underneath the car, Push the rear of the DP up and over the bracket and re-install bolt (do NOT tighten)

-Once the DP is positioned, torque the bolts at the upper flange.

-Underneath the car, torque the bolt at the rear of the DP. ( NOTE: Ensure that the DP does not contact the transmission crossmember or else it will rattle when driving.)

STEP 9: INSTALLING THE NEW EXHAUST

-Re-install each section, starting from the DP and working to the rear. Put each section being re-installed back on the hangers so it is easier to re-install.

 

Thank you so much for this detailed explanation...I too am installing an Invidia tbe so hopefully everything goes well!!!

 

Thanks alot Jake great write up!