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Old 12-24-2006, 12:38 PM   #1
chinoswrx
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Default My 1st 04 WRX Project

Well, I've had my car for about 2 years and change, and have had several bolt ons added, basics like up pipe, downpipe, y-pipe, and exhaust, and of course Ecutek, all done by the pros. My turbo after 53k miles of service has finally decided to call it quits. So I have decided to do my own uninstall and install of a turbo, of course with the help of DIYs, my best friend Chan, Nino from Gimmick Motorsports, Josh from Import Image, Bill from Mastro, Hung from Mikes Turbo. As the days go by I'll let you know how we are doing. We started yesterday and were able to take off the turbo, and unfortunately we took off one bolt that we didnt have to take off and it snapped in the process! Its the bolt that holds a bracket to where the turbo mounts onto. I'm hoping that its not going to be too significant cause I have no idea how to extract that bolt out! Next step will be getting the turbo to Hung @ Mikes Turbo in Miami to have him rebuild and upgrade the compressor wheel to a 16g. Also will be ordering a walbro fuel pump + install kit from Josh. Well....so much for this weekend..WISHN you all a MERRY CHRISTMAS!!!
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Old 12-25-2006, 05:42 PM   #2
chinoswrx
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Anyone know where I can find the following gaskets:
up pipe to turbo, turbo to downpipe, and downpipe to catback exhaust.....

THANKS!!!
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Old 12-25-2006, 06:10 PM   #3
MartinD
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Old 12-25-2006, 06:22 PM   #4
chinoswrx
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THANKS!!! anymore?
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Old 12-29-2006, 02:49 PM   #5
chinoswrx
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Well just got word that my Walbro fuel pump and install kit from Import Image, and I got in my gaskets from Fastwrx.com. Unfortunately Mike from Mikes Turbo couldnt make into town today so I'm going to have to wait till next week to get my turbo . Going to go ahead and work on the fuel pump install today, so I can get that out of the way.
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Old 01-04-2007, 10:28 PM   #6
chinoswrx
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well got the walbro fuel pump in today....wasnt that bad, but it could have been easier if I'd remove the back seat. Got word from Mikes Turbo that my lil TD04 converted 16g will be done by tomorrow afternoon....so I guess Chan and myself got some work to do tomorrow afternoon, I'll post up how it went.
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Old 01-05-2007, 02:45 PM   #7
chinoswrx
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@#$$#%! Thats how my day has gone so far..... Mikes Turbo lets me know that they cant upgrade my td04 and that my only options are 16g or 18g....$650-$675, and either one wont be in till next Tuesday. Does anyone know anyone selling a 16g locally???
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Old 01-05-2007, 04:08 PM   #8
chinoswrx
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Just ordered a td05-16g....be here on Wednesday....anyone have any experience with the 16gs?
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Old 01-10-2007, 12:06 AM   #9
chinoswrx
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Well..today I ordered some 650cc from DeatschWerks and should be in by Friday.....and tomorrow I pick up my brand new 16g, I feel like a lil kid the night before Christmas.
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Old 01-10-2007, 10:05 PM   #10
chinoswrx
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So much for feeling like a "lil kid the night before Christmas", UPS came and left and NO 16G
I swear if it doesnt come in tomorrow, I'll be in the market looking for another 16g.
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Old 01-11-2007, 08:16 AM   #11
Sharky NRK
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lol I know that feeling, you can hear the truck coming down the street....run outside with a big grin and giggles......and watch it just go past
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Old 01-12-2007, 01:22 AM   #12
chinoswrx
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LOL........well look at the time...I just got home from installing my Deatschwerk 650cc injectors....I now have 7 fingers left on both my hands, no thanks to the "Green Brackets of Death". GEEZ I hope there is no leak.....
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Old 01-13-2007, 02:48 AM   #13
chinoswrx
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Well...I'm glad to say that there is no fuel leak....and a brand spanking new 16g was finally dropped in today . Every is set for the finale.....the tune.
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Old 01-13-2007, 02:06 PM   #14
reconracer
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Were the brackets that bad, maybe i've been lucky mine and a 03 wagon I did weren't bad had brackets off and injectors seated in about 45 minutes. Doing fuel rails anytime soon? That's one install I can do but won't do for free, my buddy did his wagon unsupervised(he's not an experienced wrench either) ran for a few days and now wont turn over. Besides the point when we gonna see some install pics.
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Old 01-13-2007, 02:30 PM   #15
bl_easy
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nevermind

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Old 01-13-2007, 10:28 PM   #16
chinoswrx
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Crap... I knew I was forgetting something....pics...
Well if anyone has any questions about the install I'll be more than happy to give you some advice, I'm no mechanic but it was fairly easy once I had all the freakn parts needed. << Exception: the green brackets of death.

I did notice a small of smoke come out of the turbo side when we started her up for the first time....after the first 8minutes (egt was at about 400) the whitesh smoke appeared, we turned off the car and the smoke stopped 20sec later.....we started the car up and let it idle for another 10 minutes and nothing, no smoke.....we gave it a lil gas and kept it steady (egt rose to 600) 20sec later the smoke appeared again, went back to idle (egt decreased to 4ish) and 15 seconds later the smoke stopped. I've asked around, and I've gotten the following answers:
1: loose fittings -----double checked everything is tight and no leaks
2: burning spilled fluids -----possibly
3: turbo is burning off some type of coating that comes with from factory ---????? it is brand new....
4: turbo is burning off extra oil that was added before starting the engine----yea I put some oil in the top plug and rotated the wheel a few times
5: if my old turbo was blown I could be burning off oil that was left behind in the discharge pipes.... -----????

Anyone else got any ideas whats causing this?????
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Old 01-13-2007, 10:29 PM   #17
chinoswrx
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Quote:
Originally Posted by reconracer View Post
Were the brackets that bad, maybe i've been lucky mine and a 03 wagon I did weren't bad had brackets off and injectors seated in about 45 minutes. Doing fuel rails anytime soon? That's one install I can do but won't do for free, my buddy did his wagon unsupervised(he's not an experienced wrench either) ran for a few days and now wont turn over. Besides the point when we gonna see some install pics.
Im sorry, I was so worried about the install, being my first real project, that I forgot to take pics....but like I said before, I can help anyone out as much as I can if they need some help....
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Old 01-15-2007, 01:20 AM   #18
chinoswrx
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Anyone on suggestions on that smoke????
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Old 01-15-2007, 01:49 AM   #19
reconracer
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He me up on yahoo or aim and we can go over it im online even if i done appear to be so
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Old 01-20-2007, 11:29 AM   #20
chinoswrx
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Well...glad to say that I made it back from Tampa yesterday and the car feels amazing....I left Thursday morning, the car struggled a bit to get her up to speed but once I got it up to 70-75 it was pretty smooth sailing from there on, except for the tolls (no sunpass). I made up there with a bit more than a 1/4 tank of gas to spare. I met up with Bill @ Mastro to let him know I was there, I bought a Prodrive shift knob (mine was getting a bit old) and went to the waiting area to wait for my appt. 1/2 an hour later Bill walks up to me and ask me what I thought of the 07 tail lights...he had a buddy that was interested in trading his 07 tail lights for my 04 tail lights. We walked outside where I met Grant, who had just purchased his white 07 sti. I said "sure, lets do it", 10 minutes later our cars rear ends appearance had changed, pretty cool what a set of tail lights can do to a car....well the time came for my tune. Bill prepped the car and got in on the passenger side with all his tools. He flashed my ecu, and gives me the ok to start up her up. We take it for a little drive and already the car feels a bit better...he starts tinkering around with ignition, rpms, boost, and wastegate. After a couple more drives around the block, the car feels great, but Bill states the suby wants some more. We pull over to check out the size of the "pill" in my hose and find out there is NO PILL! (Newb mistake I more than likely chucked it when I had to replace one of the hoses). Bill pops a pill in one of the hoses and off we go again around the block...what a difference...the car response is amazing...after some more tinkering with the fuel maps and wastegate, and extending the maps two times. Bill and I were very happy with the results. At WOT we were looking at 75% duty cycle, and idle was raised to 865-875. The car felt great, it seemed to be working extremely well with the 16g and 650cc injectors, and loving the tune. Unfortunately I was not able to get the car on a dyno, but I will as soon as I find one down here im Miami. BTW, Bill....I made it back with a bit more than half a tank of gas!!! When I got to Davie, which was my first stop, I had half a tank left, and had traveled 223 miles since I filled up in Tampa! I guess this means Ecuteks new fuel efficiency program works! Im extremely satisfied with how the car feels and the way I was treated at Mastro.....LOTS OF THANKS TO: BILL (MASTRO) FOR TUNING, JOSH (IMPORTIMAGE) FOR THE WALBRO, DEATSCHWERKS FOR THE 650CC INJECTORS, NINO (GIMMICK MOTORSPORTS) FOR ALL THE ADVICE AND OVER THE PHONE HELP, HUNG (MIKES TURBO) FOR THE 16G, MY BEST FRIEND CHAN FOR HELPING ME PUT EVERYTHING TOGETHER AND PROVIDING A SAFE PLACE FOR MY CAR, AND TO ALL THE NASIOC MEMBERS WHO HELPED ME OUT IN THE FORUMS.

Last edited by chinoswrx; 01-20-2007 at 11:31 AM. Reason: grammer
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Old 01-20-2007, 12:38 PM   #21
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turbo upgrades are always fun, really brings the 2.0 to life! have fun with it!

Josh
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Old 01-20-2007, 04:30 PM   #22
jetfan8178
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Hows everything going thus far? Last time I talked to you I thought you were just about done?
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Old 01-20-2007, 09:42 PM   #23
chinoswrx
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yup... all is done...turbo upgrade, injectors, fuel pump and tune! Cant wait for the Megan coilovers!
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