Any way to install the gaskets (at the turbo) without completely tearing down the UP/DP sections? I am thinking the Downpipe would be pretty easy by just taking the DP back exhaust off the hangers (if a bit heavy), but what about the UP? Anyone know if just losening up that section will be enough for me to get the UP off the studs and slip the gasket over it?
The DP you can muscle out of the way... As for the UP... you can either drop the manifold (doubt you can loosen the nuts far enough to get sufficient clearance), or move/pull the turbo. The turbo is tethered by the oil line, oil drain and coolant lines. I don't recall if the coolant lines can move enough; the oil line will bend a bit, but you'll likely have to pull the tube out of the drain/recirc and it can be a PITA to get back in. So basically, it'll be a pain either way. Sorry. :-(
you will have to pull part of the exhaust manifold off that connects to the up but it should give you plenty of room to slide a gasket in there after that
You can drop the manifold pretty far without taking it completely off. Not sure if that would give you enough room. Just loosen all the bolts and see where that gets you. Its pretty hard also to get to all the uppipe to turbo manifold bolts without removing the dp. Dp is easy to get on and off though.