stage 4 installation: how I did it/what I think of it

[855m0n0]

Last weekend I installed a VF-22 turbo, removed/gutted/resinstalled up-pipe, removed/modded/reisntalled injectors, installed fuel pump (walbro), and tuned car with UTEC, laptop, and LM-1.
I used the installation instructions from scoobymods.com to do the install being that I had never done any of this before.

This was the order that I did things in along with the time it takes
I did spray liquid wrench the night before the install on everything.
1. remove intercooler (2 minutes)
2. remove intercooler support bracket (< 1 minute)
3. unbolt turbo from up-pipe (3 bolts) I used 2 extentions and one of those free moving extentions that allows you to work from odd angles. (2-3 minutes)
4. Unbolt turbo from downpipe. I think there were 5 bolts. 3 you can easily do from top other 2 from bottom. That free moving extention is a life saver here. (5 minutes)
5. remove oil line, be carefull not to lose washers. Remove cooant lines. Pull out turbo. (4 minutes)
From opening hood to getting turbo out was about 15 minutes total.
Now for the up pipe. Everyone said this was a PITA, but I found it super easy.
1.Use O2 sensor socket (autozone sells them) and remove o2 sensor. (2 minutes)
2. remove plastic cover under car and heat sheild from part of header that mounts to up pipe. (5 minutes)
3. up bolt 3 bolts on bottom of up pipe (3 minutes)
4. un clip sensor wire from car and pull up pipe out of car. (<1 minute)
there you have it. Removal of up pipe in under 10 minutes. Total time from start of project including a drink of water is about 30 minutes. I did not jack up my engine or any of that crap that people have talked about. I don't under stand what all the fuss is about. Maybe it is that people are doing it with out removing the turbo. It may be hard then. But, removing the turbo is a joke. anyway.
Gutting up pipe
OK this sucks. I used the instructions from scoobymods.com. It took about 2 hours to get it to a level of rattlelessness (not a real word, but you get the point) before I would let it pass exhaust to my turbo.

Injector removal. I removed the injectors with the turbo out. It was easy too. The Green brackets of death were not that hard to remove. I was so worried that I wouldn't be able to do it that I almost paid someone else to do it. Anyway.
1. Remove intake. 3 minutes.
2. Remove the passenger site GBOD. This one sucked more than the other one. It took about 8 minutes or so to get out.
3. remove washer fluid resivoir. 2 minutes or so.
4. remove driver side GBOD (this one is super easy). Took about 3 minutes to do.
5. remove 2 bolts holding down fuel rail. (<1 minute)
6. have friend pull on rail while you get injectors out. Make sure to remove signal wires from injector. That was harder for me to do with my fat fingers than to get the injector out. (3 minutes per side)
There you have it. 4 injectors out of the car in about 20 minutes. Maybe the green brackets are really hard to do with the turbo in. I don't know. Wasnt that bad.

Modify injectors
Not very hard. I used a dremel with a small cutting wheel and some needle nose to remove once it was gone. You only need to but about 1mm down all the way around on the weld line to get it to come off. I f-ked that up on one. It still works, but it doesnt look as nice as the others.
It took about 15 minutes to do this. I could do it now in less than 10 now that I know what to do.

Reinstall
I cut the line of the driver side GBOD so that I did not have to reinstall the bracket.
1. put new O rings on injectors. I did not do this 1st time and they leaked...a lot. I used ones from Autozone that were made for injectors (OK for gas. Most O rings are not) 3 minutes
2. have friend hold fuel rail while you put injectors back in. Reconnect signal wire. Bolt fuel rail down. (5 minutes per side)
3. reinstall washer fluid res. and intake stuff (5 minutes or so)
4. smile becuase you just reinstalled your injectors in about 18 minutes and did not contimplate suicide or having your friend "steel" your car.
5. put new up pipe gasket on up pipe (10 seconds) ( i didnt do this and had ugly leak, but I learned that I can get a turbo off, put on up pipe gasket and reinstall said turbo in about 35 minutes becuase of it, which I guess was worth it. But, not really.)
6. attach turbo to up pipe. There are only 3 bolts. It was kind of a bitch to get the turbo get into the intake pipe. And attaching the oil line on the bottom sucked a little. It took a good 6 or so minutes to do this. It is easier to do with someone helping you. I did it once alone and once with my buddy helping. The latter is MUCH cooler.
7. Attach coolant lines and oil line. the top one will be too short if you get a VF-22 like I did. The bottom one needed major clamping down to get it to not leek. I had to get pipe clamps for it and throw away the stock clamps. Mine leeked the 1st time I did it. The second time after figuring that out it only took about 10 minutes.
8. Attach down pipe. Use a NEW gasket becuase leaks suck. 5 minutes.
9. Reinstall intercooler. I always have trouble getting the Y pipe thing attached. It is MUCH easier to do with a friend helping. (10 minutes)
10. smile you just reinsalled a turbo and up pipe in about 26 minutes.

Walbro fuel pump.
1. remove fuel pump cover in trunk on right side. (1 minute)
2. remove cover of fuel pump. Remove lines. Don't let any thing fall into gas tank. That would be really dumb. (5 minutes)
3. pull out fuel pump assembly. Walk to work bench. Remove Walbro from box. Follow instructions on how to setup. Remove stock fuel pump. Reinstall walbro just like stock one was setup. (15 minutes)
4. Reinstall is reverse of install (10 minutes)
This takes about 30 minutes.

What I learned from all of this.
1. always replace gaskets
2. always replace O rings
3. don't believe the hype about stuff being all that hard. I had not ever done any of this before and I dont have any special tools.
4. This could very easily be done in an afternoon in your garage.

OK, now the fun stuff.

Tuning.
I drove around for 1 week with the TXS map for a VF-34 stage 4 with TXS TMIC on a UTEC 4.3(c) with injectors scaled to 740cc.
This maps really sucked for this setup. Not saying anything about TXS or their maps. Just giving an assesment of this map for my setup. Keep in mind that this map is for a different turbo, aftermarket intercooler and STI injectors. Anyway.
Tuning was fairly easy. We just hooked up LM1 to rear O2 sensor and watched data log from UTEC.
1st run. AFR was between 8.5:1 and 9.0:!. Woah!! That is super rich.
removed fuel by 1 until AFR was where I wanted it.
Added boost untill boost hit 18.5 PSI
This took about 2 hours. I didn't mess with the ignition at all (I am a chicken). I have 0 knock and the car pulls really hard. The AFR never goes leaner than I want it to under boost. BTW, I have never tuned a car before. I just followed the UTEC manual instructions, the UTEC quick user guide on WRXhackers.com and the LM-1 user manual.

Since I had no dyno, but I did have a friend that with a 350whp (have dyno chart for that one) mid 12 second 240SX I just did pulls next to him from about 10mph to 65 mph. My car was a tiny bit faster.

Now that I have had this all working for a bit here are some impressions.
VF-22 on UTEC log shows positive manifold pressure starting to happen at about 2500 rpm. (.8 psi, but it is a positive number)
I hit 18-19psi at about 4500 rpms on the logger.
I got these numbers by going to WOT at 1500 rpms in 2nd gear on a flat road and logging it. I couldnt do it 4th gear since that would put me in triple digit speeds and in jail.
It is a bit more laggy then the stock turbo (granted I had stock turbo with cat in up pipe) but it is far from what some might have you think. I have never been in a VF-30 or VF-34 turbo car but it spools faster than my friends 240SX with SR engine and GT25R turbo with FMIC and that is OK with me.
My gas mileage when not boosting everwhere (rare) is about the same as stock. The car idles at about 500-600 rpm and stays at 14.7:1 on both the LM-1 and on the UTEC logger with the modded injectors.


Overall I was ready to sell my car and get a something better (faster)before I did these mods. I almost didnt since I hear all the whining about how hard it is to do on the forums and I didnt want to pay to have someone else do it. Since I already had UTEC and 1 cat 3" custom turbo back the entire adventure only cost me $525 for new VF-22 w/gaskets (gruppe-s.com rocks btw), $90.00 for fuel pump, and $30.00 in pipe clamps, coolant, O rings and other crap. So $645.00 and I got a car that doesnt suck any more and runs like a scalded dog.

Now all i have to do is avoid the cops while under boost.

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[InfamousDX]

Good write-up!! From all that, I say that the most important thing to take away is take your time and PLEASE always use new hardware in regard to gaskets and especially injector o-rings. We found that out the hard way on my car, as I noticed you did too.

Enjoy the newfound power

[MomoWRX]

wow, very nice. Now go get it dyno'd

[855m0n0]

I am saving up for a new intercooler. Not sure if going TMIC or FMIC. Oh, the decisions. After that I am going to "street tune" it again to get it close then go to the shop and get it perfect and get a cool peice of paper that I can show off to all my friends with.

[RexRonald]

I agree swap for new gaskets when working on engine parts (metal to metal)... but quite honestly, there is zero need to replace the injector gaskets when swapping fuel injectors (unless they're already ripped/dried/cracked), i've had mine in and out several times with no problems, no leaks, always used same gaskets.... just take a little time and care while working with this area and you'll have no probs... use a very sparing amount of vaseline on the gaskets, they'll seal just fine.

Metal to metal gaskets need to be replaced with each change usually because the gaskets in between the metal parts are usually of a 'crush' type and they take the shape of the space inbetween the metal parts, unlike the flexible fuel injector gaskets, exhaust gaskets don't rebound to their original shape when removed... but now i'm only stating the obvious...

since money is usually a finite variable in the upgrades we do, don't go wasting it when you don't need to.

[greenguy]

Thanks for the write up! It will be confidence insirering for those that are a bit week in the knees to wrench on there own rides.
Good job!

[imprezavness]

gruppe-s rocks sometimes, other times they take 4 ever to ship stuff

[banzai]

Originally Posted by RexRonald

there is zero need to replace the injector gaskets when swapping fuel injectors (unless they're already ripped/dried/cracked),.

i don't agree with ^^ this guy ^^


do it anyway. it's cheap insurance.

-B

[855m0n0]

I had to go to the 24/7 autostore at 1 am to get those gaskets becuase I didnt think I would have to get new ones. Mine were not torn or anything, they just would not seal.
I spent more in gas (3 gallons at 2.10) and time ($3/hour illegal immigrant wage, I would rather be sleeping than going to autozone at 2am) getting those o rings then the purchase price of the rings.
Plus, taking the injectors out a 2nd time at 2:30 am sucks. I would spend the money and save the time. But, then again, if you can save 10 bucks and it works then rock on..

[D_Block]

Cool. Thanks for the post! It may come in handy in the next few weeks!

[InfamousDX]

Using new o-rings IS definitely CHEAP insurance. They cost like $1 each at the dealer and that's overpriced. I'd spend it for peace of mind ya know?

[imprezavness]

your one hell of a weekend mechanic dude, mad props

[Bonjo2]

Awesome job. I'm not sure I'd go as far as you with regard modifying the injectors with a dremel and then not flow testing them, but agree with most of your times. I had ailments with the atermarket up-pipe's studs, injector o-rings, injector gaskets.

Agree-liquid wrench is a lifesaver.

Let me know when your tranny goes, so I can read your tranny build write-up before I attempt it on my own.

[855m0n0]

I hope my tranny lasts a while. . . I am saving for RA gear set though. Not sure if I will brave that one or not.

[imprezive one]

good god man, you're a busy one. nice!

[pezman04wrx]

Damn man ... You make it sound so easy I want to do it this weekend ... ... Now all I need is some motovation and, oh yeah ... money ... Well, can't win them all ... Great write up though ... BTW, did you flow test your modded injectors? I'm guessing you didn't, but I've heard that if you know what they're actually flowing you can tune for it specifically and it will help out alot ...

[ride5000]

This was the order that I did things in along with the time it takes
I did spray liquid wrench the night before the install on everything.
1. remove intercooler (2 minutes)
2. remove intercooler support bracket (< 1 minute)
3. unbolt turbo from up-pipe (3 bolts) I used 2 extentions and one of those free moving extentions that allows you to work from odd angles. (2-3 minutes)
4. Unbolt turbo from downpipe. I think there were 5 bolts. 3 you can easily do from top other 2 from bottom. That free moving extention is a life saver here. (5 minutes)
5. remove oil line, be carefull not to lose washers. Remove cooant lines. Pull out turbo. (4 minutes)
From opening hood to getting turbo out was about 15 minutes total.
Now for the up pipe. Everyone said this was a PITA, but I found it super easy.
1.Use O2 sensor socket (autozone sells them) and remove o2 sensor. (2 minutes)
2. remove plastic cover under car and heat sheild from part of header that mounts to up pipe. (5 minutes)
3. up bolt 3 bolts on bottom of up pipe (3 minutes)
4. un clip sensor wire from car and pull up pipe out of car. (<1 minute)
there you have it. Removal of up pipe in under 10 minutes. Total time from start of project including a drink of water is about 30 minutes. I did not jack up my engine or any of that crap that people have talked about. I don't under stand what all the fuss is about. Maybe it is that people are doing it with out removing the turbo. It may be hard then. But, removing the turbo is a joke. anyway.

sorry man, but i'm calling bs on your "times."

a turbo and up pipe out in 25 minutes? your first time doing it?



ken

[Soon2Bgreat]

Originally Posted by ride5000

sorry man, but i'm calling bs on your "times."

a turbo and up pipe out in 25 minutes? your first time doing it?



ken

I was thinking that too, and it's not just the turbo and upipe that was fast.

[855m0n0]

you can call bs all you want. It doesnt change the fact that it did not take me long to do.
After you get the turbo out. There are only 3 bolts on the bottom of the up pipe and the front O2 sensor. With the liquid wrench sitting on there all night and a breaker bar it only takes a couple of minutes to get those three bolts off. They are all very easy to get at. You can pull the up pipe from the top of the car (engine bay). I didnt lift the engine or anything like that (the installation stuff I downloaded said I had to do that for some reason). I just reached in and pulled it out. There isn't much to it. I really don't know what all of the fuss is about.

I do have a turbo back and the stock heat sheild was never put back in. So there was no heat sheild stuff up top to deal with. Maybe that would have taken a lot of time. Maybe that is what all the hype about this thining being a PITA is about. The people that did my exhaust took that out so I don't know.

[ride5000]

if you don't take out the turbo, the up pipe must be removed from below. that's a big difference in difficulty.

i wanted to ask you how you got the turbo out without removing the downpipe from the car? all the car's i've worked on required this step.

there are TWO bolts at the bottom of the up pipe, and 5 bolts from up pipe to turbo. and you can't get the up pipe bolts off without getting the downpipe out of the way, and if you don't get the up pipe bolts off then the turbo doesn't come out.

so do you have any pointers you can throw my way for next time? i'd love to be as fast as you claim to be.

ken

[WHAT]

I think that getting the uppipe out in that amount of time is realistic, if you have the turbo already out. I had mine out in about 15min.

But when you get tuned I hope you are not thinking that you are going to put down similar numbers to your friend. You will not have 350whp.

[855m0n0]

I know I wont have 350whp. Really I dont care how much horse power it makes as long as I "think" it is fast.

Anyway.


My exhaust is custom, so it may not be exactly same for you, but basically I unbolted the down pipe and pulled it out of the way from under the car. I don't know if you can move a stock on that far or not but with my exhaust I was able to move it out of the way pretty easily. When I had my friend helping me the 1st time he guided the divorsed waste gate wall (it has an APS dump pipe) away from the turbo. The 2nd time I did it alone I just pulled back on it enough from under the car to do it.

[timman_24]

I would also say those times are a little idealistic. I just got doing the uppipe from the bottom. Maybe the liquid wrench onvernight helps, but some of those bolts can be a bitch. Also about the hoses that go to the turbo... Don't you have to flush the coolant or pinch the lines? The lines are kinda hard to get at.

Props to you though. I thought the uppipe was easier to do then most people say, too bad I had a coolant leak after words . Stupid coolant line into the turbo got pushed around...

[Gethin]

This isn't a race, 855 was stating the time it took *HIM* to do it hoping his tips would help someone else......sheesh!

[855m0n0]

timman_24 I pluged the lines to keep the coolant from running out. My friend has coolant line plugs that he got when his turbo on his 240 was out for a week. I did add coolant to the system when I was finished and made sure there was no air in the system. I forgot about that step.

Liquid Wrench is a life saver. I don't know how hard removing those bolts would be with out it. Exspcially since I drove my car up on to ramps to do it and there isn't a whole lot of room to get leverage. I just used a socket wrench with the appropriate socket on it put one foot on some part of the car that didn't look like it was going to move and pulled. It wasn't too bad. With out liquid wrench I usually end up breaking bolts so I always use it now.


I really only put the times there because after reading all of the negative posts on DIY installations of up pipes in and injectors I thought people would like to hear from someone would did it their 1st time using online instructions and how long it took. The vast majority of posts on things like the injector install are from people saying it took them hours to get the GBODs off. There is one that I read recently where the guy said it too 9 hours to do.

When I embarked on my turbo installation journey on Saturday I wondered if I would even have a car to drive on Monday. I just wanted to show people that this installation can be done in one afternoon and isnt necessarly as bad as poeple make it out to be as long as they replace O rings and gaskets the 1st time.