BNR Downpipe Install Help!

[SSonic]

I have the ZZP midpipe-back exhaust installed(Fairly Simple), but ran into issues when trying to install the BNR downpipe. Does anyone know the size of the torx socket needed to remove the turbo heat shield? Also, does anyone know if a step by step install with photos exists on the forum, and if so could you please comment the link ,as I have been unable to find one. Any tips for installing the downpipe too? Thank you!

 

[rdss]

Here's my step by step. Not pics though. You don't need to pull the heat shield.....

http://www.sonicownersforum.com/forum/185844-post8.html

I dug through 10 pages of a search for "down pipe" and couldn't find a step by step.

1) Disconnect plug from O2 sensor.
2) Remove 3 nuts from mid pipe.
3) Remove 2 mount nuts, ones the infamous Hidden Bolt.
4) Loosen the v-band clamp until the bolt has come loose.
5) Remove Factory down pipe.
6) Go backwards from "5" up but with install/tighten instead of remove. You will use the factory gasket for the DP to mid pipe connection.

 

[SSonic]

Ok...thanks a ton! Whole time I was so worried heat shield had to be removed!

 

[Twitch]

hey

I dont know if you already installed or not but heres a word of advice

just got my bnr installed 3 days ago and all 3 bolts for the midpipe connection snapped. get yourself 3 1 1/2 inch botls with nuts just in case. and the hardest part for me was the v band clamp. use lots of wd40 with the hidden bolt

 

[sonichead94]

The hidden bolt is super easy! To not complicate things just disconnect the charge pipe from the turbo. Loosen the clamp that holds it and it should come right off. Once that comes off u should have more then enough space to get into that nasty hidden bolt. Best and easiest way IMO.

 

[ecohauler]

^I had a dumb moment and the comment above was really helpful. For searchability I'm going to add the key phrase 'hidden nut' to this thread. The part you have to reach is actually a nut on a captured bolt. The phrase 'hidden nut' currently reveals one useless result on Google and the forum search excludes 'nut' for being too short a word. Hopefully this will help anyone having similar trouble in the future.

 

[JAVO]

How in the he77 did you guys get that middle nut?
I got the lower one and the bolt out of the stock band up top but that one in the middle is killing me. Theres a tube that looks like its held on with a hose clamp but I dont really see a good way to remove it to get it out of my way. I can't get a deep socket 10 on the nut and I don't have enough room to loosen once I get a wrench on it.. Any tips?

 

[rdss]

I'm pretty sure the pipe you're talking about is the hot side pipe before the intercooler and people have had luck removing that to aid in getting at the bolt. I just took my time and it finally got it off. It was quite a pain though.

 

[JAVO]

Ok ok!! The tool for the job is a flex joint ratcheting wrench.. That got it!
But I've got it out, the lower one out, the 3 that connect the next section out and the bolt that holds the band in place out but the downpipe still feels firmly in place. There a trick to getting that band loose?

 

[dvn]

You might have to just tap the band clamp or pry a bit with a screwdriver and it will pop loose.. It can stick sometimes.

 

[JAVO]

You might have to just tap the band clamp or pry a bit with a screwdriver and it will pop loose.. It can stick sometimes.

This was it exactly. I had to stick a wide blade flathead in there and twist and once it popped the downpipe became loose..
Now to put all this stuff back on.
Wish me luck..

 

[rdss]

Good luck, it goes back in a lot easier. If you have someone to support the pipe while you install the band clamp it makes things a lot easier, each time I swapped them it got easier and quicker.

 

[JAVO]

Good luck, it goes back in a lot easier. If you have someone to support the pipe while you install the band clamp it makes things a lot easier, each time I swapped them it got easier and quicker.

Each time? Why would you swap them again?

 

[Eric Smit]

different products, going to stock for the dealer, going to stock to sell.

 

[rdss]

Product development as well.

 

[JAVO]

Well I got it all bolted up last night and it sounds awesome.. Here's my setup

• MPFab Intake
• Anaconda downpipe, midpipe and high flow cat
• ZZP cat back with muffler

I had bought the heavy duty v-band clamp from MPFab too but I couldn't get the oil line out of the way to get it on properly so I ran with the stock one. I'll revisit that later. I'm sore as crap today. (broke my neck and back in the service so manual labor and I don't get along very well)

I still have the Trifecta Tune to put in place and I have a short throw shifter I'm going to save for another day.

Besides that middle hidden bolt that was a pita to get the only other really difficult task was trying to hold the pipe and get the clamp in place. I ended up having to call a friend over for a couple minutes to help me with that.

The upper O2 sensor was a sinch to remove from the plug, unscrew and lay to the side. The lower one was much more difficult. I never could get it unplugged so I just had to thread it out of the pipe which twist the line and when I went to put it back in I twisted it the opposite direction, put it in place and threaded it in so it had little to no twist in it when it was in all the way. Hoping I didn't hurt anything but I was tried, hurting and frustrated by this point so it's the only thing I could do.

If I had to nitpick about the things I don't like about my setup it would be the rotation of the muffler the oval is vertical so it seems like it hangs lower than it should and I don't like the exhaust tip. I will be removing that and replacing it with a turn down at some point. I'm going to see if I can rotate the muffler to tuck it under the car more. The dealership installed it for me when they replaced my timing chain. They messed up something in my stock exhaust and wanted to keep it another week while they ordered a factory one. I told them I had a complete cat back in my garage waiting to be installed and they agreed to install it. Its' possible the tech just didn't rotate it enough.

All in all though I'm very happy with it, it sounds great it definitely passes the butt dyno tests.

 

[Eric Smit]

get that tune in.

 

[Sonic_Boost]

Trick to remove said hidden bolt?

Got it!

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