Thanks for writing back guys! And it's good to see you're sticking with the project Pat. I can't thank you enough for the driveway install pictures.

So, I am going to a local muffler shop today at 1:00 and getting two bungs welded in. I'm removing the Cat (good 'ole South Carolina) but would there be any reason to move either sensor farther from the turbo?

 

I got the two bungs welded in to the exhaust piece this weekend and started to dissassemble the car. I realized when I tried to mount the FMIC that the "mounting brackets" that they sent didn't line up with the holes in the car OR the FMIC. So, a little delay until I can do something about that.

(It's just drilling a couple of holes, but it was dark and I was tired, so I'll get back to it when I have a chance.)

 

I got 1 screw under the front crash bar, one bolted to the horn and one bolted to the AC Condenser

 

hmm... the one screw under the crash bar... there is a hole there in my xb, but no screw so I'll have to get that and then put one in to the bottom of the IC as well. When you say "1 screw under..." do you mean one screw in the body or one screw in the IC or both?


On top, I can line up the pass. side "tab" of the IC with the condensor hole and the bracket hole. When I do, the right condensor hole lines up as well. The horn hole and the right tab hole are off. That's the two I'm drilling in the bracket.

 

Mine were off too, nothing a a lil brute force socket and a wrench couldn't fix. My IC had a bracket attached to the bottom of it that was bent to go under the crash bar, I took 1 Self Tapping Screw and ran it up into the crashbar to hold the bracket there to keep the IC from swinging back and forth. (not that it did anyway). I am taking the system apart tomorrow to fix somethings so I will take a picture then.

 

nice set up bro. congrats!

 

Thanks Intense! I'm really looking forward to enjoying the work going into this. But, I have to admit... the doing it is just as enjoyable.

Pat, I didn't get brackets like the ones you are using. I see in your pictures that you have one bracket that is spiraled (twisted) from your horn to the right tab and one that goes to the crashbar. Mine traverse the top of the condensor and attach at the horn for the top one. The bottom comes off the mounting hole in the bottom of the IC and goes straight down. It lines up with an existing hole on the front of the xb (sorry... no photo right now) that doesn't have any bolt/screw/clip/etc. in it.

This is the top piece with arrows showing the two locations that I had to drill out. (Which I've finished.) Because of the angle you can really only see one, but you can see the sharpie mark of where it should have been.



This is the bottom bracket. The red arrow goes to the bottom of the IC.


.....

On a side note, my epod came in for my two remaining gauges. I am pulling the dash again tonight to remove my boost gauge. I have to send it back and get a different one. I didn't know that Autometer offered two types in the Nexus line. The one I got is just boost and reads up to 60 psi. lol. Right... I'm gonna get a lot of use out of that gauge. The one I'm getting instead is a boost/vac gauge that goes to 30 psi. Here's a few pics of the gauges install process for the dash.


You can see the marks for the gauges...


No going back...


One down...

More updates soon.

 

Well, just so you know ... work has been way too stressful lately. I did have a chance to work a little bit on the car though and here's a few shots. Got it "torn down" and the new radiator ready to go in. You can see from the next few pics, the water temperature sending unit adaptor to go in the upper radiator hose.







I also got the new perrin crank pulley on and took a shot of the Driveshaft Shop upgrades.



(I'm aware that only the power steering belt is on in this pic. )





More updates coming (possibly after lunch) soon.

 

Ok... So, my car still sits where it was. I'm going to have to jack the rear end up to keep the tires from dry-rotting if I keep up this pace. lol...

Here's a few more pics of what's been done. I've pulled the hoses, fuel rail, valve cover, injectors, air intake and exhaust mani. cover off the car.

I had to cut the front, driver's side "hook" off so the Perrin fuel rail would fit properly. You can see where it has been cut in this picture:



While it was off, I decided to go ahead and do NinjaStance's tutorial on painting it. You can see it here - Painted Valvecover Tutorial, and here's a pic of mine finished:



I got the new injectors and fuel rail seated:



And some of the new Perrin silicone hoses installed:



I didn't leave that uncovered... I just removed it for the pic.

This weekend I hope to get back to work on this. I'll be fighting with the exhaust manifold, header and exhaust bolts to remove all of them. I'll also drain the oil to start the turbo install soon. I'll be sending more updates soon.

 

I'm writing again to respond to a few issues that came up talking to TuningIsLife on his thread. ZPI Driveway Install

There seems to be an issue that I'm trying to get my head around regarding the oiling of the turbo, as well as, removing oil from the turbo.

With the car running, the new oil pump is 'sucking' oil against gravity and back into the stock oil system. So, in this scenario there is a constant stream of oil in that line from the bottom of the turbo up to the secondary pump. As soon as you cut your power, the three feet of oil filled tube on the "out" side of the turbo and the two feet of tube on the "in" side of the turbo dump into the housing of the turbo itself to cool and sit.

I will be running a turbo timer to cool things at shutoff. If I keep the pump that came with the kit, I may use a simple relay to leave that new oil pump on an extra "x" seconds. Something long enough to relieve the "out" tube of oil. I just have to make sure to not run out of oil in the line and still be pumping. I don't want to burn the pump out either. This will just take a bit of testing to find the right amount of time.

I planned on checking the stock oil pressure my 1.5 is putting out and putting a restrictor in line for the inlet of the turbo to max it out at 40-45psi. This turbo doesn’t need a ton of oil and would prefer not to have it. But, TuningIsLife told me the kit comes with banjo bolts to take care of this. I’ll check and see. Also, if the pump isn’t pulling it’s weight I plan to switch to a 8000-643-236 Shurflo and see if that helps. I also plan on waterproofing everything down there with some black 500 degree RTV silicone. I may switch out the filter as well to a K&N snowmobile filter and sleeve cover.

All of that should take care of the “too much oil” and the “not getting rid of the oil” issues I predict occurring.

Another thing that concerns me slightly is finish on the exhaust side of the turbo. I am considering getting this ceramic coated to reduce rust. But, that may be a future modification. We’ll have to wait and see.

Anyway… man I wish that I could be there working on it. I’ll update again soon.

 

Just to let you know, the pump I am using is a 8000 series pump, though Kenny could not comfirm which model number it was exactly. If you need any help with Shurflo pumps or parts, I suggest talking to Art @ System Accessories (877) 917 1199

 

anything new on this? lets see some more posts

 

Sorry guys. I've been on vacation in South Florida, the Bahamas and Orlando the last two weeks. I'm teaching 3 yo choir at church, 3,4,and 5th grade RA's, singing in the adult choir, have a rehearsal for a wedding tomorrow, performing in a wedding Sat. and working 10 hours of overtime each week to catch up with what I missed. ... I need another vacation. lol...

I'll get back to work on it soon. Maybe next weekend will open up some free time for me. The next endeavor is to finish pulling the exhaust, exhaust mani. and mounting the new exhaust/turbo/header setup. (dry lines) I'll have some more pics and info for everybody soon.

Just an update Tuning... the pump I've got is a Shurflo 8000 series as well. I'm not sure about the banjo bolts deal, but there are in there. I'll work all that out after I hang it.

I promise this hasn't gone by the wayside. Thanks for checking in!

 

BUMP FOR YOU!

 

Update Time!

Ok... so where was I... If I re-cover something, sorry.

I've got the entire exhaust completely off the car. I've mounted the new header. I've put the newly painted, black valve cover back on with the front ear cut off to fit passed the fuel rail, which it did just fine. I've got the new radiator mounted and all the silicon hoses on. I've temporarily mounted the oil pump and my new Earl's fittings came in today to plumb the oil lines. So, the next step will be to pull the oil pan and start drilling. I'm running the oil back through the pan with a bulkhead fitting. I loosely mounted the piping that goes from the IC to the throttle body with the mass air sensor on it.

So, oil lines and IC piping will be the next update hopefully. I've got to get all the mechanical things and out of the way to start the electrical soon.


Here's an overall view of some of the progress.

And now some issues...
First off the mass air sensor placement on the charge pipe is about a 1/4 inch farther away than the wiring harness plug for it will reach. So, I've got to see if pulling it out of the split loom will give it more play to connect or find out if I'm going to have to extend that harness.

Also, the other sensor plug that is next to the MAF plug goes to something to do with vaccum. Here it is :



Originally this piece mounted to the plastic air box. I have to figure out a way to mount this thing back in the car without the air box.

The final problem I'm currently having that's holding me up has to do with holes in the turbo. Do all the threaded holes have to have something in them or be plugged!?!? Here's an image of the turbo with a circle around one of the two holes in question. On opposite sides of each other are a set of two holes. Two have plugs and two are open and threaded. Are these extra points to mount the turbo to a bracket or do these have to be plugged somehow? Any help will be amazing.



My next issues will be vaccum lines. I have to figure out how to run these for the stock application/bov/and wastegate.

Thanks to anyone still looking who hasn't given up completely on me yet.

 

jeez.... turbo setup looks very complecated. what about tuning?

 

Complicated ! Blah ! I did it in my driveway in just over 2 days by myself. :-D

 

Thanks for the vote of confidence there Pat... lol

I know it's been a while since I've been around. But, she's still sitting there waiting on me. I've got to figure out these open holes on the turbo problem. Anyone got any thoughts? (See post above)

Hope everyone is doing well.

P.S. - I'm going to need a Bride Racing baby seat. :0p We're having a girl!

 

two are for the water lines two are for the oil lines

 

curious to see how this runs......