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://i24.photobucket.com/albums/c2...einstalled.jpg
http://i24.photobucket.com/albums/c2...inlet_pipe.jpg
http://i24.photobucket.com/albums/c2...pe_removed.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://i24.photobucket.com/albums/c2...manifold_1.jpg
http://i24.photobucket.com/albums/c2...manifold_2.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.
