Forced Induction Turbo Install Begins Now!

Turbo Install Begins Now!

Wanted to start a new thread since we're starting the install in a couple of minutes. Tonight we're just going to form a game plan of attack and figure out what questions to ask. I want to use this forum as a means of bringing the whole foum togather to solve problems with the TSI kit as I go. Also there is a welth of knoledge between us all so I figured if I was going to have this turbo done by Monday night I'm going to need all the help I can get.

Question?

Q) The eManage install document at http://www.mohdparts.com/emanage/install/corolla/emanage-install-98-up-corolla.pdf is really awesome but it shows how to hook up the MAP sensor? My car doesn't have a MAP sensor, it has a MAF sensor? Is it the same wire and readings or do I need revised instructions? Trav?

Q) What is the torque spec for the bolts on the turbo header when I'm using ARP studs? I don't want my turbo manifold to fall off and I don't want to strip the studs.

Q) Should I use thread locker on the manifold bolts? I have Locktite blue? is that good enough?

Thanks.

Wish me luck guys!

First few pics
Garage where the work shall be done, notice Vortex's instructions pinned on the back wall, THANKS TRAV!

This is the old girl before we even pop the hood to start screwing around

The first wave of turbo parts

ask trav about the emanage..as for the head bolts..I dunno what the torque specs are on them, but it's pretty hard to strip those threads on those bolts.

How many pounds is "but not too much"?

Gotcha Thanks.

Okay, so here is the word. So far the turbo install is going really poorly, The downpipe that is labeled for 99-02 corolla does not fit at all and the heat core inlet/outlet touches the turbo housing when it is installed so you cannot fit the hoses on them and the engine head has a lift point that blocks the turbo waste gate preventing the turbo from bolting up. So my installer friend being the die hard person that he is has ripped out my dashboard, ecu, harnesses, firewall coverings so he can remove the heater core and cut and relocate those inlet/outlet's to avoid the turbo and we're going to chop off the engine lift point because its pretty useless since we have a hook and bolts. And then the only thing that will be blocking me is the downpipe which I'm about to send mail to Turbokits.com right now about. Scary stuff but I'm too far to turn back now.

damn dude...that blows...sorry to hear that your having a hard time with the install...hope everythng turns out ok real soon.

I'm sure with Jesse at TurboKits.com working with TSI we'll come to some quick resolutions. But its obvious that TSI has not installed this kit on a 2001 Corolla so they will have to correct the downpipe and a few fitment issues. I'll keep you all posted though. Tomorrow is a new day.

Sorry to say it but that's typical TSI build quality.

I guess that settles the question about fitment then. If you're already having trouble, I can tell you that it's only the beginning.



-Doc

sorry to hear that man

Well Jesse from TurboKits.com is going to call me back shortly and try to help me sort this out with TSI. It may just be an issue of mis-labeled downpipe and slight differences in the dashbored layout between 98-02 Corolla's. My installer already completely removed my dash so he can get at the heater core to alter the inlet and outlet to avoid the turbo and we have a solution for the 2nd problem with the anchor point on the head but the we need a replacement downpipe or we're dead in the water. I'll keep you all posted.

Dash torn out, man I never thought I would see my car this way. My installer is going to run all my eManage and guage wires with the factory harnesses


Bare Dash, woah!(


Picture of head with header removed


Picture of turbo manifold resting in its place on the studs, noticed the coolant lines going though the firewall being right at the turbine, we're going to fix this today

I agree. But this is an experiement to help TSI and TurboKits.com resolve the issues with this kit so a little modification and playing around will be necessary.

My installer does not have a "gung ho attidtude to rip shit apart". He was finding solutions to problems and felt comfortable taking the dash apart. Plus he wanted to run all the eManage and boost controller harnesses with the factory wiring harnesses which I think is awesome. I think considering the situation he is doing a kick ass job. And he has worked for years in a speed shop installing turbos and engine upgrades and on top of that he does custom fiberglass work, painting and anything else you can think of car related. He is good at this kind of thing and I trust him. He is also the same guy that did my Porsche Xenon projector conversion and that turned out sweet as hell. And he built my custom fiberglass 7" touch screen dash trim and relocated my head unit. Sorry if I sound a little defensive but I've known the guy for years and have seen all his work and I've never seen him fail at anything.

That means this kit in its present state will not install on 98-02 Corollas because of the heater core issue & downpipe issue. Thanks for confirming this. Sound like TSI will have to modify there manifold to clear the heater core inlet or outlet. But for my installation because I dont have time for them to re-design and re-cast a manifold will probably result in the heater core inlet/outlet being re-tooled which I don't have a problem with to keep the install going. Today we're going to get the manifold mounted without the down pipe and run the IC piping to ensure proper fitment. I'll post more pictures later.

I agree that modification to this degree should not be necessary but without a new manifold we have no choice. They will still have to fix the manifold to make this kit compatible and I will provide them with all the information they need to fix the kit however so we can continue we gotta brave though it all Your kit does sound awesome that it only requires 2 modifications and I think that totally kicks ass and I hope that when I finish with TSI there kit only requires 1 modification (oil pan tap). Because we all need a good 98-02 turbo kit and this is our only hope for now until you can mass produce your own kit But I do like the way you kit looks in the picture above, very nice!

You should goto eMachineShop.com and build your KIT in there fab tool and see how much it would cost. Because then you could just ship orders to them and have them make the kits

good luck with the install dude, hopefully everything will go accordingly and remember slowly but surely

The kit that turbokits sold you is for 2003 + corollas. It looks like they never tested their kit on the 1998 -2002 corollas, but good lock with the install and hope everthing can be solved for future kits.

Every single part in the kit they sold me has a sticker on it including the downpipe that says "98'-02' Corolla", It doesn't even list 2003 as being compatible But I tend to think you might be right that everything was mislabled and I actually have a 2003 kit. Do you have the TSI Extreme kit?

No, I have a custom setup that I put toguether, I should say me and the welder that did the piping.

^^ seeing as none of the TSI parts fits anyways that would've been much less of an headache.