IV: Detailed installation pics
Previous exhaust installation instructions can be seen here:
AWE exhaust installed - photos and impressions
Turbo access is easy once the intercooler is off
Turbo hardlines and ducts removal. Use female and male torx sockets to loosen 5 hardlines from the turbo. I used a small chisel or screwdriver to help lift the flanges of these lines off the turbo. There is enough flex in the lines to push them off the body. The compressor ducts unscrew from the rear (inlet) tube and unclip from the side (outlet) tube. Careful not to hurt any of the O-rings on any of the lines. AWE very thoughtfully provided all new Viton O rings but I reused the old ones. Also remove the EGT probe with a 14mm wrench
Stock header being removed. Remove this first to allow easier turbo removal. Install new header after new turbo installation. Use liberal amounts of PB blaster for 2-3 days prior to attempt. Also, Passenger side headers is very close to the oil tank - end bolt can be accessible with a 1/4" drive 13mm socket since the 3/8" drive sockets are too wide to clear.
Header removed. Exhaust ports are exposed, as is the turbine inlet of the turbo. I used carb cleaner to remove some of the carbon to ensure a clean mating surface for the new headers. The new AWE headers are perfectly matched in size to the exhaust ports ensuring uninhibited flow.
New header installed. Beautiful contours. The primaries and collector are matched in size to the head and turbo to ensure optimal flow. Good access in maintained to all mounting bolts. Do not tighten the header in place until the turbo is fitted to the lines and exhaust - you need some play here to get the turbo flanges to fit over the studs, then tighten everything down
Diverters are removed from the stock turbo. Just unfasten 3 10mm bolts. Reassemble to new turbo with a dab of blue or green loctite
Swap out the oil reservoir. Held in place with 2 torx bolts. Replace O ring with new one thoughtfully provided in kit
Intercooler fitment - old intercooler cores are smaller than the new ones. The stock cores are recessed inside the frame of the intercooler, whereas the new ones are flush. The ducts need to be trimmed with a utility knife to allow the ducts to fit flush and clamp properly. The plastic is thin so trimming is a breeze - maybe 10 minutes
