F-Body Instruction Manual for "Ebay" Turbo Kits!
05-24-2012, 11:28 PM
#1
F-Body Instruction Manual for "Ebay" Turbo Kits! Hey guys, I forgot that when I originally did an Ebay kit, I prototyped it for the company, and in exchange for me making instructions, I'd get the kit at cost. I was cleaning up my files and found this! Hope it can help somebody....
Mods: I wrote this and own the content, so no, there is no copyright violation.
Turbocharger Installation Instructions
for 98-02 LS1 Camaro & Firebird
IMPORTANT, READ THIS FIRST: Study these instructions completely before proceeding. Engine and/or turbocharger damage may occur if any component within these instructions is improperly installed. Fatboy Garage, Godspeed, or any of its distributors cannot be held responsible for damages as a result of negligence or improper installation. This turbocharger system can be installed using common tools and automotive procedures, but the installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle. If in doubt, consult a knowledgeable turbo installer. Check local laws regarding aftermarket modification to emission controlled vehicles. Remove the turbocharger kit from its carton and inspect for any obvious physical damage. All kit components are thoroughly inspected and carefully packaged prior to shipment from the factory. If any shipping damage is evident, contact your supplier and request that they process a claim with the shipper involved
Before proceeding, it is recommended to have the following items:
• GM F-body (Camaro/Firebird) repair manual
• A large table / workbench
• Standard selection of automotive tools
• Plenty of adjacent available workspace
• The ability to lift the vehicle safely (Floor Jack and Jack Stands)
• RTV sealant, Synthetic Oil and oil filter, engine coolant, Teflon Tape
Additional items recommended:
• MSD spark plug wires
• Spark plug wire heat shields & header heat wrap
• NGK TR6 spark plugs
• High flow fuel pump & new fuel filter
• 42-60 lb/hr high impedance fuel injectors depending on desired boost and power output
• Gauge pod with boost and wideband air/fuel ratio gauges
• Solid motor mounts due to heat
• Thin “pusher” style fans (stock fans cannot be re-used)
Removing Stock Components:
1. Remove ignition coils with bracket to allow removal of spark plugs.
2. Remove all stock exhaust components and emissions equipment.
3. Remove intermediate steering shaft.
4. Remove all intake components, leaving only the throttle body.
5. Refer to service manual to remove front bumper cover.
6. Remove radiator and electric fans.
Installing Oil Feed and Return Lines:
1. Refer to service manual for removing the oil pan.
2. Remove the oil filter adapter plate from directly above the oil filter and drill a hole allowing oil to flow from the cavity through the neck. Using a tap, cut threads to the appropriate size fitting. 1/8 NPT is common.
3. Using a stepped drill bit, drill a hole large enough to allow a 90° fitting to be tapped into the pan. Hole must be ABOVE the oil level to allow the turbo to drain properly. Run as large of an oil return as possible. -12 is common
Installing Turbo “Hotside”:
1. It is recommended that all hotside turbo piping be wrapped with thermal header wrap. “Hotside” refers to manifolds, crossover tube, merge tube, and downpipe. (3) 50 foot rolls will cover all piping.
2. Crossover pipe will need a new 02 sensor bung welded in. Any exhaust/muffler shop can do this for you.
3. Starting with passenger manifold, working your way over to the driver’s side, install right manifold, crossover, left manifold, and turbo merge pipe. (Note** leave all bolts/connections loose until ALL parts have been installed. This will allow for adjustment.)
4. The passenger manifold V-band connection may need to be notched to clear bell-housing. Drivers side manifold may need front bolt hole elongated with drill or dremel to align properly.
5. Install turbocharger with metallic gasket between flanges. Oil drain port (larger port) must be angled down.
6. Install spark plugs and wires before installing downpipe.
7. Install wastegate with a small tube venting to atmosphere.
8. The wastegate flange on the downpipe will need to be cut off and welded shut. Any exhaust/muffler shop can do this for you.
9. Install lower downpipe through motor mount area. (k-member might need to be lowered slightly – refer to service manual)
10. Install upper downpipe to turbo outlet and connect to lower downpipe via V-band clamp. Power-steering lines may need to be bent slightly out of the way.
11. **Larger turbos may require a custom downpipe.
12. Re-install steering shaft.
13. Once alignment is satisfactory, tighten all manifold bolts to manufacturer’s specifications and tighten all V-band clamps.
Installing Turbo “Coldside”:
1. “Coldside” refers to the intercooler, intercooler piping, and silicon connectors.
2. Attach a cone filter to the air inlet of the turbo.
3. Using silicon connectors, direct the intercooler piping towards the passenger side of the engine bay.
4. Cut an access hole in the plastic shield and route piping around the frame rail towards the front of the car.
5. Move horns so that they do not interfere with piping. Vacuum reservoir from air conditioning may need to be relocated.
6. Remove metal bumper support, measure the widest point of the intercooler, and cut a section out of the front to allow the intercooler to mount inside of the support. Do not cut the top portion of the support.
7. Measure the mounting tabs on the intercooler and drill holes through the top of the bumper support and use bolts to secure the intercooler to the support.
8. Route piping from other side of intercooler up through a hole underneath the fuse block. (fuse block may require slight trimming of plastic)(air injection pump and all hoses must be removed)
9. Mount blow off valve in the piping close to the throttle body. (adapter pipe must be used or *weld flange to existing intercooler piping **aluminum welder required)
10. Low boost applications can use the stock mass air flow sensor. High boost applications must run a 2-bar speed density tune which eliminates the mass air flow sensor, yet requires a 2-bar map sensor. Mount various silicon connectors according to application.
11. Install stock intake air temperature sensor in the aluminum tubing near the throttle body. Stock grommet style can be used with low boost applications. High boost applications must use a threaded intake air temperature sensor.
12. Once all routing is complete, tighten all T-bolt clamps.
Mods: I wrote this and own the content, so no, there is no copyright violation.
Turbocharger Installation Instructions
for 98-02 LS1 Camaro & Firebird
IMPORTANT, READ THIS FIRST: Study these instructions completely before proceeding. Engine and/or turbocharger damage may occur if any component within these instructions is improperly installed. Fatboy Garage, Godspeed, or any of its distributors cannot be held responsible for damages as a result of negligence or improper installation. This turbocharger system can be installed using common tools and automotive procedures, but the installer must have a thorough knowledge of automotive engine operation and feel comfortable working on the vehicle. If in doubt, consult a knowledgeable turbo installer. Check local laws regarding aftermarket modification to emission controlled vehicles. Remove the turbocharger kit from its carton and inspect for any obvious physical damage. All kit components are thoroughly inspected and carefully packaged prior to shipment from the factory. If any shipping damage is evident, contact your supplier and request that they process a claim with the shipper involved
Before proceeding, it is recommended to have the following items:
• GM F-body (Camaro/Firebird) repair manual
• A large table / workbench
• Standard selection of automotive tools
• Plenty of adjacent available workspace
• The ability to lift the vehicle safely (Floor Jack and Jack Stands)
• RTV sealant, Synthetic Oil and oil filter, engine coolant, Teflon Tape
Additional items recommended:
• MSD spark plug wires
• Spark plug wire heat shields & header heat wrap
• NGK TR6 spark plugs
• High flow fuel pump & new fuel filter
• 42-60 lb/hr high impedance fuel injectors depending on desired boost and power output
• Gauge pod with boost and wideband air/fuel ratio gauges
• Solid motor mounts due to heat
• Thin “pusher” style fans (stock fans cannot be re-used)
Removing Stock Components:
1. Remove ignition coils with bracket to allow removal of spark plugs.
2. Remove all stock exhaust components and emissions equipment.
3. Remove intermediate steering shaft.
4. Remove all intake components, leaving only the throttle body.
5. Refer to service manual to remove front bumper cover.
6. Remove radiator and electric fans.
Installing Oil Feed and Return Lines:
1. Refer to service manual for removing the oil pan.
2. Remove the oil filter adapter plate from directly above the oil filter and drill a hole allowing oil to flow from the cavity through the neck. Using a tap, cut threads to the appropriate size fitting. 1/8 NPT is common.
3. Using a stepped drill bit, drill a hole large enough to allow a 90° fitting to be tapped into the pan. Hole must be ABOVE the oil level to allow the turbo to drain properly. Run as large of an oil return as possible. -12 is common
Installing Turbo “Hotside”:
1. It is recommended that all hotside turbo piping be wrapped with thermal header wrap. “Hotside” refers to manifolds, crossover tube, merge tube, and downpipe. (3) 50 foot rolls will cover all piping.
2. Crossover pipe will need a new 02 sensor bung welded in. Any exhaust/muffler shop can do this for you.
3. Starting with passenger manifold, working your way over to the driver’s side, install right manifold, crossover, left manifold, and turbo merge pipe. (Note** leave all bolts/connections loose until ALL parts have been installed. This will allow for adjustment.)
4. The passenger manifold V-band connection may need to be notched to clear bell-housing. Drivers side manifold may need front bolt hole elongated with drill or dremel to align properly.
5. Install turbocharger with metallic gasket between flanges. Oil drain port (larger port) must be angled down.
6. Install spark plugs and wires before installing downpipe.
7. Install wastegate with a small tube venting to atmosphere.
8. The wastegate flange on the downpipe will need to be cut off and welded shut. Any exhaust/muffler shop can do this for you.
9. Install lower downpipe through motor mount area. (k-member might need to be lowered slightly – refer to service manual)
10. Install upper downpipe to turbo outlet and connect to lower downpipe via V-band clamp. Power-steering lines may need to be bent slightly out of the way.
11. **Larger turbos may require a custom downpipe.
12. Re-install steering shaft.
13. Once alignment is satisfactory, tighten all manifold bolts to manufacturer’s specifications and tighten all V-band clamps.
Installing Turbo “Coldside”:
1. “Coldside” refers to the intercooler, intercooler piping, and silicon connectors.
2. Attach a cone filter to the air inlet of the turbo.
3. Using silicon connectors, direct the intercooler piping towards the passenger side of the engine bay.
4. Cut an access hole in the plastic shield and route piping around the frame rail towards the front of the car.
5. Move horns so that they do not interfere with piping. Vacuum reservoir from air conditioning may need to be relocated.
6. Remove metal bumper support, measure the widest point of the intercooler, and cut a section out of the front to allow the intercooler to mount inside of the support. Do not cut the top portion of the support.
7. Measure the mounting tabs on the intercooler and drill holes through the top of the bumper support and use bolts to secure the intercooler to the support.
8. Route piping from other side of intercooler up through a hole underneath the fuse block. (fuse block may require slight trimming of plastic)(air injection pump and all hoses must be removed)
9. Mount blow off valve in the piping close to the throttle body. (adapter pipe must be used or *weld flange to existing intercooler piping **aluminum welder required)
10. Low boost applications can use the stock mass air flow sensor. High boost applications must run a 2-bar speed density tune which eliminates the mass air flow sensor, yet requires a 2-bar map sensor. Mount various silicon connectors according to application.
11. Install stock intake air temperature sensor in the aluminum tubing near the throttle body. Stock grommet style can be used with low boost applications. High boost applications must use a threaded intake air temperature sensor.
12. Once all routing is complete, tighten all T-bolt clamps.
Trending Topics
05-25-2012, 05:46 PM
#9
Need to add in
- throw away the dp that comes in the kit and fab your own
- throw away the v-band gaskets that come with it , they just make it worse
- make a custom power steering line , stock one will melt and catch on fire
I recommend to anyone looking at a eBay kit , to just buy the hotside, buy a on3 t76, cx racing intercooler and pipe kit, you will need at least 60# injectors and I highly recommend converting to a return style fuel system with a 1:1 fpr
Oh and most important
BUY A QUALITY WASTEGATE
- throw away the dp that comes in the kit and fab your own
- throw away the v-band gaskets that come with it , they just make it worse
- make a custom power steering line , stock one will melt and catch on fire
I recommend to anyone looking at a eBay kit , to just buy the hotside, buy a on3 t76, cx racing intercooler and pipe kit, you will need at least 60# injectors and I highly recommend converting to a return style fuel system with a 1:1 fpr
Oh and most important
BUY A QUALITY WASTEGATE
05-25-2012, 07:07 PM
#11
This for the PTK knockoff?
If so forgot to mention:
Need to slot and enlarge header bolts. manifolds do not line up correctly on heads.
02 bung may be welded wrong on pass side. Kit i seen had bung interfering with starter
Xover pipe may rub transmission bellhousing.
Gaskets and hardware are not reccomended for use. Shipped with grafite headers gaskets and 3/8-16 header studs
If so forgot to mention:
Need to slot and enlarge header bolts. manifolds do not line up correctly on heads.
02 bung may be welded wrong on pass side. Kit i seen had bung interfering with starter
Xover pipe may rub transmission bellhousing.
Gaskets and hardware are not reccomended for use. Shipped with grafite headers gaskets and 3/8-16 header studs
05-26-2012, 02:11 AM
#12
This for the PTK knockoff?
If so forgot to mention:
Need to slot and enlarge header bolts. manifolds do not line up correctly on heads.
(IN THERE)
02 bung may be welded wrong on pass side. Kit i seen had bung interfering with starter
(IN THERE)
Xover pipe may rub transmission bellhousing.
(IN THERE)
Gaskets and hardware are not reccomended for use. Shipped with grafite headers gaskets and 3/8-16 header studs
(Yes I agree on that)
If so forgot to mention:
Need to slot and enlarge header bolts. manifolds do not line up correctly on heads.
(IN THERE)
02 bung may be welded wrong on pass side. Kit i seen had bung interfering with starter
(IN THERE)
Xover pipe may rub transmission bellhousing.
(IN THERE)
Gaskets and hardware are not reccomended for use. Shipped with grafite headers gaskets and 3/8-16 header studs
(Yes I agree on that)
05-26-2012, 02:16 AM
#13
Need to add in
- throw away the dp that comes in the kit and fab your own
(Another good option)
- throw away the v-band gaskets that come with it , they just make it worse
(Gaskets? Mine never came with v-band gaskets...?)
- make a custom power steering line , stock one will melt and catch on fire
(Agreed. I wrote this more for the super cheap user, so everything in there is assuming youre being as cheap as possible.) If it was me I would just not but an ebay kit in the first place LOL
I recommend to anyone looking at a eBay kit , to just buy the hotside, buy a on3 t76, cx racing intercooler and pipe kit, you will need at least 60# injectors and I highly recommend converting to a return style fuel system with a 1:1 fpr
Oh and most important
BUY A QUALITY WASTEGATE
- throw away the dp that comes in the kit and fab your own
(Another good option)
- throw away the v-band gaskets that come with it , they just make it worse
(Gaskets? Mine never came with v-band gaskets...?)
- make a custom power steering line , stock one will melt and catch on fire
(Agreed. I wrote this more for the super cheap user, so everything in there is assuming youre being as cheap as possible.) If it was me I would just not but an ebay kit in the first place LOL
I recommend to anyone looking at a eBay kit , to just buy the hotside, buy a on3 t76, cx racing intercooler and pipe kit, you will need at least 60# injectors and I highly recommend converting to a return style fuel system with a 1:1 fpr
Oh and most important
BUY A QUALITY WASTEGATE
06-12-2012, 09:21 AM
#17
Launching!
Join Date: Jun 2009
Posts: 235
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Can you run poly motor mounts with this kit? I have a bmr Turbo k member and don't know if solid mounts will work.
Could you wrap the turbo with a on3 blanket to help with the heat?
What is the best size turbo to run with this kit? T76 or 67mm? Don't really know that much about turbos...will any T4 work?
Could you wrap the turbo with a on3 blanket to help with the heat?
What is the best size turbo to run with this kit? T76 or 67mm? Don't really know that much about turbos...will any T4 work?
06-29-2012, 05:34 PM
#18
TECH Addict
iTrader: (2)
for the 2 bar MAP, how high is high? im planning on keeping mine under 10psi for now but if i get a 2bar MAP, would i still have to have it SD tuned or would it stil work correctly? just wondering.
06-29-2012, 08:23 PM
#19
Can you run poly motor mounts with this kit? I have a bmr Turbo k member and don't know if solid mounts will work.
Could you wrap the turbo with a on3 blanket to help with the heat?
What is the best size turbo to run with this kit? T76 or 67mm? Don't really know that much about turbos...will any T4 work?
Could you wrap the turbo with a on3 blanket to help with the heat?
What is the best size turbo to run with this kit? T76 or 67mm? Don't really know that much about turbos...will any T4 work?
any T4 will work, turbo size is dependent on your HP goals
you can still run a MAF, but I prefer my SD.
