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Old 06-04-2004, 01:11 AM   #1
crk4
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Member#: 43617
Join Date: Sep 2003
Location: Florham Park, NJ
Vehicle:
1976 Ford Bronco
R.I.P. Mark Vos, 96 ob

Default Custom TD04 Turbo Kit Price and Parts List

Guys: Please feel free to modify this basic list for a basic turbo kit. Please whoever has done something similar, please reply and lend your tech support/experiences. We need some newcomers!!! I stumbled upon this one a while ago and decided maybe someone would like to see it.


Custom TD04 Turbo Kit Price and Parts List

1 Used TD04L-13G from a $150
USDM WRX
bought used at http://i-club.com/forums

2 Earl's -10AN Weld-in Fitting $7.69
Part #EAR-967110
http://www.summitracing.com

3 Russel 45deg. -10AN Hose end $17.95
Part #RUS-610110
http://www.summitracing.com

4 Russell 3' 10AN Braided Steel hose
Part #RUS-632150 $17.50
http://www.summitracing.com

5 Bosch 1" outlet BOV $45
http://saabperformanceparts.com

6 370cc Nissan Silvia Injectors $120
(check sr20deforum.com
and freshalloy.com for used sets)

7 USDM WRX Fuel Pump $50
(check nasioc.com/forums or i-club.com)

8 Custom Stainless Steel $175
up-pipe
from Chad Stamper http://uniquemotorsports.com

9 Custom Stainless Steel $240
downpipe
from Chad Stamper http://uniquemotorsports.com

10 Catco Universal Catalytic Converter
Heavy Duty 2.5" inlet/outlet $99
Part #CTO-8006
http://www.summitracing.com

11 Custom 2.5" downpipe-back exhaust
$450

12 Borla 2.5 catback exhaust

13 MidPipe -- Downpipe to catback exhaust


14 WRX Intercooler $150
http://i-club.com/forums

Custom charge pipe should be made.

15 bolts for IC/Turbo charge pipe $0.66
6mm-1.0 x 20mm
Home Depot SKU 30699 35788

Autometer Sport-Comp Gauges

17 Fuel Pressure 100PSI $75
Part #3309

18 Boost -30 to 25PSI $50
Part #3301

19 EGT to 1600F $106
with probe included
Part #3365
http://optauto.com

20 Autometer Dual or Triple 2 1/16" A-Pillar Pod
Part #20590 $30
http://nipponpower.com

21 Rumblesoft Carbon Fiber Air Intake and Turbo to Intercooler Pipes:
Part #IHATEKURT $250 ($100 in Carbon Fiber and
http://rumblesoftracing.com hours of pain, suffering
 and epoxy-induced hallucination)

Various Plumbing Stuff:

22 3-2.5" Silicone reducer
http://www.bakerprecision.com $19.99

23 2.5"-2.25" Silicone reducer
http://www.bakerprecision.com $18.99

24 2" Hump Hose x 2 $40
http://www.roadraceengineering.com

25 Brass Tees (Coolant lines) x 2
(Home Depot) $10.43

26 6 ft. 5/8" Heater hose
(Pep Boys) $6.99

27 3 ft. 3/4" Heater hose
(who needs samco BOV
and vacuum hoses!&@)
(Pep Boys) $5.99

28 Home Depot Catch-can $10
JB Weld some PVC drain piping together,
add 1/2 OD fittings and route
the valve cover breathers to it.

29 3" Band Clamp x 4
(Home Depot) $2.96

30 2" Band Clamp x 4
(Home Depot) $2.40

31 1" Band Clamp x 10
(Home Depot) $4.50

32 Bag of Zip ties
(Home Depot) $1.99

Electronics you might want, but don't absolutely need:

33 J&S Ultrasafeguard Ver. II - $495
http://www.jandssafeguard.com
(I'd recommend this if you opt not to use a standalone ECU)

34 Apex'i SAFC - $200
(you can get these used all over the place.
nasioc.com/forums)

35 Some sort of boost controller. - $50-500

36 Greddy E-Manage Fuel and Timing Piggyback computer $450

As far as whats left to finish my kit, I will have to modify the stock wastegate for 5 psi, clock the turbo (td04), fabricate a charge pipe, buy a fuel pump, some type of injectors that will fit my 96 2.2l intake manifold, install my e-manage and my Autometer boost & EGT gauges. Today I just ordered the WRX oil pan and am soon going to order the return and feed lines[] and connections to be welded to the pan.
Changing WasteGate down to 5 PSI
The conection between the wastegate actuator rod and the wastegate is threaded. You have to unclip the actuator rod from the wastegate and turn the end of the rod. Shorter=more longer=less. Then with the boost gauge you can check what it is set at, and it won't go any higher than that.


C H R I S
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Last edited by crk4; 06-04-2004 at 03:54 PM.
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Old 06-04-2004, 02:41 AM   #2
White 2.5rs
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99RS TWE&SCAT EJ257
Hydra+HMist+PPG+35R=DEATH

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u got raped on that turbo man
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Old 06-04-2004, 02:43 AM   #3
White 2.5rs
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Hydra+HMist+PPG+35R=DEATH

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also adjusting the arm like that will DESTROY ur spool up time
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Old 06-04-2004, 02:50 AM   #4
benjaminetanyahoo
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Join Date: Aug 2003
Chapter/Region: Tri-State
Location: Midtown West (Lincoln Center)
Vehicle:
2000 New York
MTA

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do Nissan injectors work on 2000+ fuel rails and are they high impedance? Just curious
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Old 06-04-2004, 03:18 AM   #5
Kostamojen
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Galaxy Blue Sexy

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Last edited by Kostamojen; 06-12-2004 at 06:47 PM.
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Old 06-04-2004, 07:09 AM   #6
Hitokiri
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Join Date: Oct 2000
Chapter/Region: NESIC
Location: CA
Vehicle:
1999 2.5RSt
RBP

Default

nice list guys! Keep truckin!
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Old 06-04-2004, 11:11 AM   #7
NeaD
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Member#: 43371
Join Date: Sep 2003
Chapter/Region: MWSOC
Location: St. Louis, MO
Vehicle:
1998 Impreza 2.5RS-T
Hydra User, Blue

Default

Good write up, I'll link you guys with my setup and prices when I get some time.

-Jon.
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Old 06-04-2004, 12:15 PM   #8
White 2.5rs
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Join Date: Jul 2003
Vehicle:
99RS TWE&SCAT EJ257
Hydra+HMist+PPG+35R=DEATH

Default

taping the header is EASY i dont know y people freak out about it all u need is a reference chart like 1/4" npt uses a 22/42 <no thats not the size just an ex.> either buy/borrow that bit and tap and it just works itself

dont do it on the car
i dont care how many poeple tell u its ok theyre stupid and metal bits WILL get into everything
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Old 06-04-2004, 01:05 PM   #9
ExecNav
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Member#: 30554
Join Date: Nov 2002
Chapter/Region: South East
Location: Ellijay, GA
Vehicle:
08 LGT Spec.B
01 Impreza RS-T

Smile What I have so far...

  • $315 - Greddy E-Manage w/ all harnesses, software support, and usb
  • $120 - TD04 Turbocharger
  • $70 - WRX Intercooler
  • $9 - Charge Pipe
  • $60 - WRX Exhaust Manifold
  • $0 - WRX Up-Pipe
  • $0 - WRX Down-Pipe
  • $0 - WRX Cat
  • $0 - WRX Y-pipe
  • $55 - WRX Waterpump, T-Stat, and housing
  • $20 - WRX Turbo Inlet
  • $40 - WRX Power Steering Pump
  • $19 - Remote PS Reservoir
  • $25 - WRX Fuel Pump
  • $150 - RC 440cc Injectors, clips, and spacers
  • $145 - Greddy bov (Custom adapter)
  • $70 - Stainless Steel Oil-Feed Line
  • $15 - Weld-on Fitting for Oil-Drain Line
  • $150 - Engine Cradle
  • $25 - Poly Steering Rack Bushings
  • $380 - ACT Stage 1 Clutch
  • $53 - Autometer Boost Gauge
  • $180 - Autometer EGT/AF Gauge
  • $0 - Custom Brushed Aluminum Gauge Bezel
  • $200 - Blitz Axle-back and Custom 2.5" Intermediate
  • $25 - 5/16" Fuel Injection Hose
  • $0 - Barb adapter for fuel rails
  • $8 - 3/8", 1/4" heater hose
  • $5 - Vacumm Line
  • $50 - Fuel Injection/Standard Hose Clamps
  • $30 - Kartboy Exhaust Hangers
  • $15 - T's and Barb Fittings

-Brett

Last edited by ExecNav; 07-07-2004 at 02:11 AM.
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Old 06-04-2004, 03:21 PM   #10
Darshu
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Join Date: Jun 2000
Chapter/Region: NESIC
Location: Exile in Norcal
Vehicle:
98RS w/ EJ207
2010 Mazdaspeed3

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Wow, that's my list from 3 years ago, so factor that in to the pricing Also, adjusting the wastegate actuator arm really didn't hurt all that much. Anyway, party on
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Old 06-04-2004, 04:00 PM   #11
crk4
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Member#: 43617
Join Date: Sep 2003
Location: Florham Park, NJ
Vehicle:
1976 Ford Bronco
R.I.P. Mark Vos, 96 ob

Default

Hey guys:

The guy from the Subaru dealer parts department told me that I'm making a mistake by thinking that the 2002 WRX oil pan is going to work with my 96 ej22 engine.

WHO HAS USED THE WRX PAN BEFORE ON A BIGGER ENGINE?

He said the WRX pan will NOT bolt up to the 2.5...and also that the STI pan is different.

So who is right? Only real proven answers please.


Have a good weekend,


CHRIS
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Old 06-04-2004, 04:08 PM   #12
Darshu
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2010 Mazdaspeed3

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The STi oilpan is different in shape, but the flange where it bolts to the block is the same, as far as I know. Anyway, that's not relevant to the question you're asking, which is "will a WRX oilpan bolt to my Phase 1 EJ22 block" and the answer to that is yes.
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Old 06-04-2004, 04:09 PM   #13
ExecNav
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Chapter/Region: South East
Location: Ellijay, GA
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01 Impreza RS-T

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Edit: too slow.

-Brett

Last edited by ExecNav; 06-04-2004 at 04:33 PM.
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Old 06-04-2004, 04:58 PM   #14
crk4
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Join Date: Sep 2003
Location: Florham Park, NJ
Vehicle:
1976 Ford Bronco
R.I.P. Mark Vos, 96 ob

Default

Thanks Darshu thats the answer I was looking for. A few more questions:

How will I be able to supply coolant to the turbo and where on the engine will it come from?

Will Legacy turbo fuel rails/injectors be sufficient for 5 psi on this engine? Any suggestions? The RC Engineering ones look nice but I dont know if they will fit my intake manifold.

Will STI engine mounts stop my car from sort of "bucking"...I dont know how to describe it...when I floor it then if I let off quick its a really quick jerking. What will make this go away?


Scoobaru RS: For what reason did you buy the WRX water pump, thermostat and housing, power steering pump?

Thats it for now,


CHRIS
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Old 06-04-2004, 05:32 PM   #15
ExecNav
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Location: Ellijay, GA
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01 Impreza RS-T

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Quote:
Originally posted by crk4
Scoobaru RS: For what reason did you buy the WRX water pump, thermostat and housing, power steering pump?
I have to use the water pump because the outlet on the stock RS waterpump faces down, which prevents me from using the WRX exhaust manifold (runs to the front rather than straight back like the RS manifold). The outlet on the WRX waterpump is on the front away from the manifold. The thermostat housing has a different bolt up pattern than the RS, so I have to use the housing as well.

As far as the powersteering pump, since I'm using the WRX up/down pipe and turbo, the turbo is positioned so that the inlet is facing under the intake manifold, since that's how the WRX turbo inlet is routed. The RS power steering reservoir and purge control valve is mounted on the front of the manifold. These have to be relocated to accomodate the turbo inlet. I decided to use the WRX pump because it had the lines and everything I needed.

-Brett
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Old 06-04-2004, 08:12 PM   #16
Kostamojen
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Quote:
Originally posted by crk4
How will I be able to supply coolant to the turbo and where on the engine will it come from?

Will Legacy turbo fuel rails/injectors be sufficient for 5 psi on this engine? Any suggestions? The RC Engineering ones look nice but I dont know if they will fit my intake manifold.
The EJ22T injectors should be fine, yes.

The coolant can be taped from one of the coolant lines. I plan on using the extra pump lines on the WRX water pump though.

Quote:
Originally posted by crk4
Will STI engine mounts stop my car from sort of "bucking"...I dont know how to describe it...when I floor it then if I let off quick its a really quick jerking. What will make this go away?
CHRIS
Actually some aftermarket differential bushings (Ala whiteline) and a sti tranny mount (which I think your car can use, im not sure) should cure that. Engine mounts dont usually do a whole lot for drivetrain thuds, which I had too just like yours and went with the whiteline diff bushings and a DIY eurathane filled tranny mount which cured them.
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