Turbo Build

[rstare]

I decided to make a thread for my turbo build.

I realize this needs to go in the Turbo conversion sub forum, but I cant post there.

So I have just about recieved everything I need except....
The sfmu and wideband (which are on the way, should be here soon).
The turbo and oil lines which Im ordering very soon and actually still havnt decided on. And the Intercooler, which I am picking up from Hahns on Thursday.

Things I have recieved
255lph hp fuel pump/Manual Boost Controller/Boost gauge/Oil pressure gauge/FCD/Triple Pillar (for gauges)/420a t3 turbo manifold/38mm wastegate/315cc injectors

I decided that I didnt want to just wait and install everything at once, because honestly Im getting to anxious.
I decided that I will post some detailed installs of just about everything I do, plus im sure Im going to have questions, so I can just do it all here.


The fuel pump I started to install sunday night, then I came to the conclusion that the fuel line is the devil and just isnt going to come off. (My friend is a body builder, benches about 350 and he couldnt get it off). So tonight Im jacking up the car and taking it off at the forward point. So you can expect me to post that tonight/tomorrow morning.
Getting a camera is hard at my house but Im really going to try to post pictures and explain how I did everything to for future reference.

-----Thanks to everyone who has helped me out so far! (I really dont think I would have ever turbo'd my 420a if it wasnt for this forum and the people here, so really thanks alot!
Ryan

BTW my goal is to be turbo by August 4th, it was August 1st but shipping time I dont think is going to allow it.

 

[rstare]

Well, last night didnt work out to well... I forgot about having to drill a new hole in the bracket. And my drill was at work so.. oh well. So me and my friend are going work on it Saturday instead. A few hours worth. But I plan to get the fuel pump, fcd, and gauges in.
Sorry I didnt get that up today, by next week though for sure.

 

[benjimatt]

what are you thinking about for your turbo

 

[chris712vt]

Good luck Ryan. Let me (or anybody) know if you run into a problem, we can probably help.

Just relating to what you've started so far - do attack the fuel line from under the car. If you try to unscrew the fuel line fittings right under the access plate above the tank, the hose will twist so much you probably won't get it all the way unscrewed. I was able to break the connection loose when I did mine, but never unscrewed it from there becuase the fuel line got all knotted up. If you go from under the car one of the fittings spins freely so once you break the connection loose it's as simple as unscrewing the line.

Also, I didn't have to drill a hole in my bracket when installing the walbro 255 hp... some do, some don't. Yours may fit fine with the original hole, just try it out before drilling.

 

[chris712vt]

what are you thinking about for your turbo

*cough* GT3082R *cough*


I wish I had one

 

[Car_guy_09]

Looks like you have done allot of planning And like chris said, If you need any help let one of us know Im also wondering what turbo your going to run.....

*cough* GT3082R *cough*

Allergies huh?

 

[TalonESIT]

Bullseye BW S256.. look it up... Great results!!

 

[rstare]

Well guys I picked up the fmic, all the piping, bov, ect. yesterday, man was it a trip down there. I wasnt in my eclipse at the time but I wish I was. Wide open roads straight as far as you can see without anyone in sight, not that i would speed or anything
But ya I got all of it and my anxiety has doubled once agian. I have done more planning then I thought possible, and really I learned so much stuff from this site. Like I said on saturday, or perhaps even tonight... hopefully, Im going to get started. Start with the fuel pump, and then Im going to put my gauges in, also got my wideband. Just to get it out of the way. FCD, sfmu, injectors, and so on from there. Still aiming for august 4.
So is changing injectors a pain? Cause Im guessing Im going to have to pull the intake manifold, well Im sure there is a walkthrough somewhere on this site.... just another reason for how much I love this site.
As for turbo, here is my future plans, this winter I plan on rebuilding the engine. So obviously then I am going to get a bigger turbo, so right now I am wondering if I should just get a ebay turbo since in 3 months this one will be history anyway. I really like the GT3076r for the future, i think thats what it is(I could be way off actually, with the numbers) . The funds are getting a little shorter, and I still have to buy all the little misc. stuff, vac lines, fuel line, and so on. Let me know what you guys think and I will check out all your suggestions.
Sorry, this is really long i just realized.
Ryan

 

[rstare]

GT3082R = a little out of the price range right now. I would love to save up for a month or so and get a nice turbo, but I cant wait that long, . Its probably a bad thing Im so anxious but I cant help it, you guys that turbo'd yours know what I am talking about.

Edit: GT3082R = alot out of the price range, actually, .

 

[chris712vt]

haha yeah if you're looking new a 3076 or a 3082 will be like 1300 or so, maybe more.

anyway I know what you mean. I really really wanted a 3076, that was my plan all along, but I couldn't afford it when i was ready to go turbo. I "settled" for a t3/t04e 50 trim but it's still a nice turbo. keep an eye on the classifieds... nt and turbo, and on 2gnt. bound to find someone selling a decent turbo for a fair price.

btw, I'm in agreement over your while build process minus the turbo idea. IMO it's not logical to waste a few hundred on a crap turbo for temporary purposes, then a lot 6 months from now on another. look for something in between that will be good, last, and be enough for you to be happy with for a while, or just look real hard for a good one someone is selling used.

 

[chris712vt]

Also don't forget your oil lines and fittings. i've got a helpful diagram of that too... might as well post that one too for future reference by others.

You must be logged in to view this image or video.

 

[rstare]

I actually saved that picture, I saw it before at some point. I actually saw a used t3/to4e i was really condsidering getting, thats probably what i am going to get actually.

 

[chris712vt]

haha yeah i was bored one night while i was unable to work on the car, so i tool a pic of my oil fittings to make a diagram. i took a pic of all my stainless fuel lines and AN fittings too but never made a diagram with them. anyway good luck with the turbo choice.

 

[rstare]

Well I got the sfmu now, didnt really get around to working on the car at all today, so 2morrow is the day. I need the turbo, oil feed/return kit, and misc. fuel and vac line, a breather filter... probably some other little things im forgetting. But otherwise, its all just waiting to go in.
Ryan

 

[rstare]

So, I will have some pictures to put up later.
But I had a friend come over and help and we decided to put the intercooler on.
The hardest part is getting bumper off, really. I had all the bolts out and it was still on good, but it actually goes onto the frame, I will have pictures up later. So got the bumper off, and the fog lights out, got rid of all the saftey plastic crap, moved those coolant lines, I think its actually the line for the power steering, I dont understand why it has to go out infront of the radiator like that but, we the lines behind the metal peice that it is originally screwed to. (The intercooler fit much better once we did that) I got the hahns intercooler, so we put the screws in and mounted up the intercooler. Started to figure out how the pipes would run and decided we should see how the bumper would fit on. THis is where the problem occured.
So im sure as most of you know the bumper wont go on with the intercooler. It seems to me like the black hard plastic (i dont know how to describe it, agian I will have pictures later) the thing that the bumper mounts to that is attached to the poles that go into the frame. Well it seems to me that that hole black plastic thing is going to have to come off. It also seems as if I am going to have to trim down the part on the front bumper that lips inwards. I think I am going to have to trim that down in order for the bumper to fit. Tell me if I am wrong about any of this.
I will have pictures up later, but for now I am going to get the piping run, which is harder then it should be, hahns didnt give me instrcutions, but with a little brains and trial and error I should be able to figure it out.
Ryan

 

[TalonESIT]

So, I will have some pictures to put up later.
But I had a friend come over and help and we decided to put the intercooler on.
The hardest part is getting bumper off, really. I had all the bolts out and it was still on good, but it actually goes onto the frame, I will have pictures up later. So got the bumper off, and the fog lights out, got rid of all the saftey plastic crap, moved those coolant lines, I think its actually the line for the power steering, I dont understand why it has to go out infront of the radiator like that but, we the lines behind the metal peice that it is originally screwed to. (The intercooler fit much better once we did that) I got the hahns intercooler, so we put the screws in and mounted up the intercooler. Started to figure out how the pipes would run and decided we should see how the bumper would fit on. THis is where the problem occured.
So im sure as most of you know the bumper wont go on with the intercooler. It seems to me like the black hard plastic (i dont know how to describe it, agian I will have pictures later) the thing that the bumper mounts to that is attached to the poles that go into the frame. Well it seems to me that that hole black plastic thing is going to have to come off. It also seems as if I am going to have to trim down the part on the front bumper that lips inwards. I think I am going to have to trim that down in order for the bumper to fit. Tell me if I am wrong about any of this.
I will have pictures up later, but for now I am going to get the piping run, which is harder then it should be, hahns didnt give me instrcutions, but with a little brains and trial and error I should be able to figure it out.
Ryan

You do have to trim the black plastic. If you received instructions with your hahn radiator it also show what you need to cut and trim down.

 

[rstare]

You do have to trim the black plastic. If you received instructions with your hahn radiator it also show what you need to cut and trim down.

I actually just got hahns intercooler, couldnt resist. So they didnt give me instructions. Im going to make the measurments tomorrow and trim it down.

 

[rstare]

The first picture is how it it looks now. The second picture is showing what I will have to trim down and take out. The black peice I think I am going to remove completly, then I will just put the bars that slide into the frame back in. And then the lip part more to the bottom (the top of the picture tho) I am going to trim down enough for it to fit. This will all be done today.
I thought the piping would be easy but its turning into a pain. Does anyone have a hahns stage 2 turbo setup with the fmic? Agian I didnt get instructions and there technical support isnt open on weekends. But if one of you guys could just get me a picture of which pipes go where, it would save me alot of time.
By the way http://www.rcaz.com/rcaz/sub index...per/bumper.htm is where you need to go when your taking your bumper off. (if you dont know to take it off i mean). I was going take pictures of removing it till i found that, so I just decided to post the link.
Anyway im going out now to get started.
Ryan

 

[UrN2nd]

yeah the black bumper is pointless if you get in a wreck that thing isnt gonna make a difference.... i pulled off the brackets that mount to the frame also..... you dont have to pull your manifold for the injectors there are two 13mm bolts holding the rail to the manifold. after you pull the rail its plug and play. the fcd is easy the safc is aggravating, the fmu go ahead and mount it above the fuel filter so you dont have to extend the return line to the engine bay, makes it easier since the return line is a few inches long. the fuel pump you dont have to drill a hole in the bracket just cut the line shorter, and also getting the fuel line from the top is very easy just use 2 flare nut wrenches and it wont twist, oil lines just ebay those, dont worry bout waiting till everything gets there it will be a longer biuld then you think so start with what you got. go ahead and mount the manifold once the turbo is there then return line and downpipe, run ic piping soon to check fitment. but everything is easy just look into a missing link bc our maps arent made for boost even with a fcd you will damage your map..... i did 3 420a turbo upgrades so ask with any question

 

[cs82685]

yeah the black bumper is pointless if you get in a wreck that thing isnt gonna make a difference....

It's not pointless, it's to prevent damage in low impact collissions. Regardless it's definitely easier to just remove it

just look into a missing link bc our maps arent made for boost even with a fcd you will damage your map

I have never heard of anyone having problems like this

 

[rstare]

Okay, well the black peice is removed. I put the poles back into the frame, just cause, well I saw some other people do it, . The lip is just waiting to be trimmed, I would like to get the ic pipe on now, but I dont know if its going to happen. Gauges are next, I have to figure out how to run this electric oil pressure gauge, me and electric stuff just dont work, but I have some buddies to help me agian.

 

[UrN2nd]

quote "I have never heard of anyone having problems like this"

ok thats not the point ok this thread...... but bc i got called out do some research and find out the point of the missing link. its a check valve not only to prvent the map from reading boost but to prevent the map from touching boost...... its much easier for the map to be fooled electronically, but to put more research and development into producing the check valve type meens there is ###### a lil more to the piece of equipment then you think....... but you boost your map all you want,,,, sooner or later it will go out.... the reason is not old equipment but a sensor made to read vacuum is now being subjected to 10-15 psi (or whatever your running) .. dont take this as me being an a hole im just clearing up a misunderstanding.

 

[VelocitàPaola]

quote "I have never heard of anyone having problems like this"

ok thats not the point ok this thread...... but bc i got called out do some research and find out the point of the missing link. its a check valve not only to prvent the map from reading boost but to prevent the map from touching boost...... its much easier for the map to be fooled electronically, but to put more research and development into producing the check valve type meens there is ###### a lil more to the piece of equipment then you think....... but you boost your map all you want,,,, sooner or later it will go out.... the reason is not old equipment but a sensor made to read vacuum is now being subjected to 10-15 psi (or whatever your running) .. dont take this as me being an a hole im just clearing up a misunderstanding.

You've exhibited sound reasoning, but the phenomenon you described isn't widely observed. In fact, you're the only person I've ever heard mention this problem... have you ever witnessed it first hand or are you speculating?

Fuel cut defenders are by far the more popular choice with 420A's. Despite your assertions, missing links are incredibly simple devices prone to mechanical failure.

 

[rstare]

Ok, got the bumper all modified and on, that is the first picture. The piping is just being a absolute pain. I am going to call hahns tomorrow and see if they can help me. If this is going to be too much of a pain im going to just get custom piping, which I wish i would have done now in the first place. But this is my dd so I had to get it all back and operatable for the week. Tomorrow I am going to put the fuel pump in.

The intercooler piping, there is four peices, I posted pictures of all four peices at the bottom. I assume that the peice with the spot for the bov would connect to the intake manifold. When I put that peice on it goes to where the stock intake goes, the very bottom picture. I took all that crap out, the stuff that the fuse box mounts to. So then the problem is getting a 90 coupler through that hole where the fuse wires go. Im assuming im going to have to cut a bigger hole so it can fit. But either way I cant get any of the other pipes to line up with that 90 coupler. Anyone else who has worked with a hahns fmic kit, if you could just tell me what you did that would save me alot of time. (It seems like all the people who post pictures of their install all have smic). I dont even know which is the "in" or the "out" on the intercooler. Any help is appeciated.
Thanks guys,
Ryan

 

[rstare]

So I cant post another picture, exceeded limit, and the url isnt working, but the other pipe, is longer similar to the one with the bov spot on it.
Ryan