2.5L turbo build

this will serve as a dedicated thread to me turboing my car...

um, i am a VERY lenghty guy, and i can be a bit extensive while writing, so i'll try to tone it down and keep it to a minimum.

anyways, on to few words a lots of pics! :D

this is a thread to document the turbo build that will be taking place on the following days.

UM will be the tuner. The "kit" is a DIY.

here are some "old posts" from vortex:

updating with tracking info:

-Injectors: ETA Friday

-intercooler: ETA Friday [same box]

-BIG order: thursday the 5th

the fact that the intercooler will arrive on friday, kinda pushes everything back a little bit, sorta.

On thursday:

-change wastegate spring

-remove EJ headers

-measure the oil fittings and connect to turbo

-remove oil and oil pan

-bolt on the exhaust manifold

-bolt on the turbo

-Turbo intake

-Turbo downpipe

-mock the wastegate pipes

-mock the charge pipes

Friday:

-ship ECU

-install intercooler

-do pipes from Throttle body to IC

-do pipes from IC to turbo

[what ever i didnt do on thursday]

Saturday

-weld all the pipes

-remove intake manifold

-polish intake manifold and timing cover

-connect the injectors

-wire tuck

Sunday

start putting everything back together

Next week:

connect the gauges

=========

until everything is PERFECT, i will drive with no hood (easier to do all the pipes and stuff) no front bumper and no underside cover.

it should help with temps a bit too. :D

============

i expect to be completely done by friday the 14th.

==================

boost gauge

just a couple of angles of the turbo+mani+ waste.

i still need to clock the turbo.

My fave

just some turbo pics...

turbo oil feed

on the turbine, "hot side", here is where the downpipe will connect to.

Compressor, "cold side". The big thing on the middle is where the intake goes/is.

signal for wastegate, it can be capped if un used

compressor out. Here is where the charge piping begins.

oil return

oh, i forgot to add these are some future-ly upcoming goods...

Eboost 2

http://www.turbosmartusa.com/product/e-boost-2

vent pod for the eboost 2

http://www.osirusa.com/mm5/merchant.mvc?Screen=PROD&Product_Code=VGTI-OPOD-MONL&Category_Code=VJETIA

pod for the afr (to be rolocated)

http://www.ecstuning.com/Volkswagen-Jetta_V--2.5/Search/Boost/ES5955/

http://forums.vwvortex.com/showthread.php?4942416-Turbosmart-E-boost-2-Installed-w-Gear-Dependent-Boost

Since i just spent a TON of money for the entire turbo set up, i cant go with this right now... but i will buy them on a couple of months. :D

----------------------------------------------

From here on, its all about turbos and the turbo build.

The BIG box

Silver Tial BOV

V-band flanges, v band clamps, reducers, t-bolt clamps for silicone (2", 2.5" and 3"), and oil lines

Some pipes and silicone

more pipes

Turbo with oil lines connected. Oil feed and oil drain ready to be fed!

The place where dreams will be built! :D

this is just some pics for my excitement. placement of pipes and such isnt final.

I is too excited.

Replies

Alex Crousset - September 5th 2012

Can't wait to see this running Federico. Keep it up!

Federico Tamayo - September 5th 2012

noob mistake #1: oil inlet has no restrictor...

lol.. and i forgot to buy silicone boost lines!

Federico Tamayo - September 6th 2012

schedule:

On thursday:

To do:

-change wastegate spring

-remove EJ headers

-remove oil and oil pan

-bolt on the exhaust manifold

-Turbo intake

-Turbo downpipe

-mock the wastegate pipes

-mock the charge pipes

-remove hood

-remove front bumper

-remove wheel well

Done:

-measure the oil fittings and connect to turbo

-bolt on the turbo

Federico Tamayo - September 6th 2012

ok, so today has been a little hectic, but i will start in a couple of hours: The tear down.

So far, i have 99% of it all.... tomorrow i'll have the intercooler and injectors. But if everything comes out right, i migt have the turbo bolted, with intake and downpipe today. With oil fittings as well.

right now its homework time, then i can stay up to 2 am working on the car...

some pics of it all:

The operating table: all the pipes: Stainless steel 304 .065" walls, mandrel bent.

[img]http://sphotos-b.xx.fbcdn.net/hphotos-ash4/301275_4043790528005_259707509_n.jpg[/img]

90 degree bends: 3.0", 2.5", 2.0" and 1.5" for the waste

[img]http://sphotos-a.xx.fbcdn.net/hphotos-snc6/262974_4043791048018_498865651_n.jpg[/img]

45 degrees and straights

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash3/549666_4043791568031_679349757_n.jpg[/img]

table #2: clamps, silicones, oil sealant and exhaust gasket

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash4/404086_4043792008042_1255358640_n.jpg[/img]

by having the gasket, i can technically bolt in the manifold ASAP! :D

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash4/184140_4043792208047_1965065856_n.jpg[/img]

tear down in 2 or 3 hours.

Federico Tamayo - September 6th 2012

[b]

small progress... i was bored of HW and went to work for 10 mins...

pre assembled. still have to buy the heat protection for the line. things will likely change position

[img]http://sphotos-b.xx.fbcdn.net/hphotos-ash3/560960_4044427743935_2133437816_n.jpg[/img]

compressing the wastegate to remove/change spring

[img]http://sphotos-b.xx.fbcdn.net/hphotos-snc6/251596_4044428023942_128053925_n.jpg[/img]

bolts out

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash4/402333_4044428583956_152303601_n.jpg[/img]

is it fuked?...

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash4/303579_4044428983966_1370338504_n.jpg[/img]

view #2

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash3/538615_4044429343975_1372809747_n.jpg[/img]

view #3

[img]http://sphotos-b.xx.fbcdn.net/hphotos-ash3/554634_4044429583981_2069293851_n.jpg[/img]

springs: small one is the permanent one: .5Bar = 7.252 PSI

[img]http://sphotos-b.xx.fbcdn.net/hphotos-ash3/523424_4044429903989_125248334_n.jpg[/img]

[/b]

Federico Tamayo - September 7th 2012

well.. i only worked 2 hours, but did a LOT on it. i had no clue i was this fast! :laugh:

i guess i'm too used to working on the car... Dont know if this is good or bad.

well, onto the pics:

removed the diaphragm and ordered a new one... it looked weird

[b][img]http://sphotos-b.xx.fbcdn.net/hphotos-ash3/523322_4045204723359_2067101397_n.jpg[/img][/b]

stuff removed.

[b][img]http://sphotos-a.xx.fbcdn.net/hphotos-ash4/316825_4045204923364_558900879_n.jpg[/img][/b]

wheel well removed

[b][img]http://sphotos-a.xx.fbcdn.net/hphotos-snc7/383215_4045205003366_308551380_n.jpg[/img][/b]

bumper removed

[b][img]http://sphotos-b.xx.fbcdn.net/hphotos-ash4/396162_4045205163370_223360508_n.jpg[/img][/b]

ecu removed

[b][img]http://sphotos-b.xx.fbcdn.net/hphotos-ash3/534289_4045205363375_1366132653_n.jpg[/img][/b]

bolts removed

[b][img]http://sphotos-b.xx.fbcdn.net/hphotos-prn1/564292_4045205483378_406314329_n.jpg[/img][/b]

oil removed

[b][img]http://sphotos-b.xx.fbcdn.net/hphotos-snc6/208015_4045205643382_47980129_n.jpg[/img][/b]

headers unbolted, as mentioned i needed to remove the exhaust to remove this.. i'll do it tomorrow

[b][img]http://sphotos-a.xx.fbcdn.net/hphotos-snc7/424696_4045205763385_1044641665_n.jpg[/img][/b]

engine bay mock up: intake

[b][img]http://sphotos-a.xx.fbcdn.net/hphotos-prn1/530193_4045205963390_1057140227_n.jpg[/img][/b]

note the manifold inlet! :D

[img]http://sphotos-a.xx.fbcdn.net/hphotos-ash4/310422_4045206083393_47686454_n.jpg[/img][/b]

how does it looks?

[b][img]http://sphotos-a.xx.fbcdn.net/hphotos-ash3/545917_4045206203396_141115818_n.jpg[/img][/b]

schedule:

On thursday:

To do:

-bolt on the exhaust manifold

-Turbo downpipe

-mock the wastegate pipes

Done:

-change wastegate spring

-Turbo intake

-remove EJ headers

-remove oil and oil pan

-mock the charge pipes

-measure the oil fittings and connect to turbo

-bolt on the turbo

-remove front bumper

-remove wheel well

tomorrrow:

Friday:

-ship ECU

-install intercooler

-do pipes from Throttle body to IC

-do pipes from IC to turbo

-remove exhaust

-install turbo! :D

Top

Article Information

Technical Info-DIY

By Federico Tamayo
Event Organizer

On September 5th 2012
Viewed: 641 times

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