my 5sfte project

tstoney82 · 07-18-2009, 12:29 AM

so i started my project yesterday. i started off by taking off the existing headers and exhaust. (i actually did this weeks ago, i just got too busy with other things to get around to doing the rest.) with the exhaust out of the way, i connected the turbo manifold, turbo, and downpipe. as i was connecting it up, i noticed a cooling line bracket was interfering with the wastegate. (posted a thread about this) after some careful thought, i used a 16 oz hammer and some big a$$ pliers and bent it out of the way. wastegate was no longer an issue. so everything got bolted down.

next step was to install the injectors. this was looking to be the biggest pain in the anus i have ever seen. my friend dante and i looked at it for a while as we drank a beer. we debated on taking the intake manifold off. that turned out to be a bad idea, so we decided against it. using the two brains we had, we chose to just loosen the fuel rail, pry it out and forcefully remove the old injectors. this was the best idea ever. thank god dante was around because doing that by myself would have not happened. i just wasnt in the mood for it. so anyways, the injectors were installed and the fuel rail was then put back in place. we bumped over he motor to check for leaks....no leaks....good to go.

intercooler time. after looking for the mounting bracket for an hour, we finally found it in the bottom of the box that Cavanagh sent it in. (that should have been the first place we looked but we were looking at the table where all the other parts where. my bad for not taking it out of the box) the intercooler acted like it didnt want to go in, but after removing the throttle cable from the junction box, it was pretty simple. the intercooler piping was the problem of the night. piecing it together was easy, but having clearance for the hood to close and the BOV to not touch the cold pipe wasnt happening. it was clearly time for another beer. beer number 2 (while working on the car, number 6 for the night) was magical. "lets cloak the turbo" dante says. "word. i should have thought about that 30 minutes ago." but the beer was worth it. so we cloaked the turbo about 2 or 3 inches towards the front of the car.....perfect placement for everything. the intercooler pipes where then installed and ready for boost.

after that, we decided to call it a night. our kids were tired and our wives were complaining about us being in the garage all night. (typical women sh*t) so tomorrow is another day and we will be back on the grind. looks like cooling and oil lines followed by vacuum and electrical tomorrow. if its not done by monday, it will definitely be done by next weekend.

MR2enV · 07-18-2009, 11:44 AM

im glad to hear your puttin it all together... remember not blowing up is in the tune... gotta pull timing back and get that air fuel on point....

1stgen · 07-18-2009, 12:01 PM

pix or it never happened....grats on starting the project. These ones are always fun. I will be starting this if my wife doesnt wreck my 2 while I am gone "on vacation"

tstoney82 · 07-18-2009, 03:42 PM

im gonna take some pics in a little bit and put them up.

tstoney82 · 07-18-2009, 06:35 PM

ok here are some crappy pics. one of the turbo, one of the beautiful tubular manifold hiding under the piping, and one of the whole engine.

1stgen · 07-18-2009, 07:45 PM

looks like fun cant wait to try to blow mine up. then ill have room for a v6 :P

tstoney82 · 07-18-2009, 08:59 PM

yeah i was planning on working on it a little more tonight, but i got stuck watching the kids while my wife is at the hospital with her brother. thats one more day without the two. oh well, thats just gonna motivate me to work harder and longer tomorrow.

tylerh86 · 07-19-2009, 03:46 PM

where did u get the turbo kit from, and what motor do you have

tstoney82 · 07-19-2009, 08:14 PM

i got the kit from forum member cavanagh. the motor is the 1991 stock 2.2l 5sfe n/a motor

killermillermr2 · 07-19-2009, 11:13 PM

All right man! Your IC piping is ran about the same as mine. I just got that U bend in and my janky original setup out.

I found it was easier to get the injectors in and out if you take the valve cover off. Gives your hands way more room and a straight shot at the fuel rail.

MR2enV · 07-19-2009, 11:39 PM

I would have done a trunk mount intercooler setup.... there would be alot more room in the engine bay.... I hated hoe I had to take out the piping everytime I had to change, replace, or fix something around the pipes...

1stgen · 07-20-2009, 03:07 AM

or you could just rig up the intercooler to be on the other side of the car....instead of cutting holes in the trunk. That is how I figure IM going to be routing my piping..all shoved in one corner..

MR2enV · 07-20-2009, 09:44 AM

yea thats how my setup was.. the intercooler and piping on the driver side vent

tstoney82 · 07-20-2009, 07:14 PM

thats a good looking setup you got

MR2enV · 07-20-2009, 09:37 PM

nice setup i had to be exact........you have some of it and saintg2000 has the rest

tstoney82 · 07-21-2009, 12:43 PM

you are also running a 2.0. ive got the good old 2.2. my intake manifold would probably allow for more space on the drivers side if i had that setup, but the setup i have is good for now. i wasnt really in the mood to custom make brakets or anything.

killermillermr2 · 07-21-2009, 10:47 PM

I thought this might be a better place to answer your question. Are you talking about the down pipe?

YELLOW_MR2 · 07-22-2009, 12:17 AM

Quote:

Originally Posted by MR2enV

yea thats how my setup was.. the intercooler and piping on the driver side vent
http://i548.photobucket.com/albums/i...v/IMG_1927.jpg
http://i548.photobucket.com/albums/i...v/IMG_1886.jpg

Thats a great looking set up, I set my IC in the same place

I think we even have the same manifold.

killermillermr2 · 07-22-2009, 12:19 AM

^ I was wondering when you were going to pipe in with that

YELLOW_MR2 · 07-22-2009, 12:52 AM

LOL its been piped in for a long time.

07-18-2009, 12:29 AM	#1 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	my 5sfte project so i started my project yesterday. i started off by taking off the existing headers and exhaust. (i actually did this weeks ago, i just got too busy with other things to get around to doing the rest.) with the exhaust out of the way, i connected the turbo manifold, turbo, and downpipe. as i was connecting it up, i noticed a cooling line bracket was interfering with the wastegate. (posted a thread about this) after some careful thought, i used a 16 oz hammer and some big a$$ pliers and bent it out of the way. wastegate was no longer an issue. so everything got bolted down. next step was to install the injectors. this was looking to be the biggest pain in the anus i have ever seen. my friend dante and i looked at it for a while as we drank a beer. we debated on taking the intake manifold off. that turned out to be a bad idea, so we decided against it. using the two brains we had, we chose to just loosen the fuel rail, pry it out and forcefully remove the old injectors. this was the best idea ever. thank god dante was around because doing that by myself would have not happened. i just wasnt in the mood for it. so anyways, the injectors were installed and the fuel rail was then put back in place. we bumped over he motor to check for leaks....no leaks....good to go. intercooler time. after looking for the mounting bracket for an hour, we finally found it in the bottom of the box that Cavanagh sent it in. (that should have been the first place we looked but we were looking at the table where all the other parts where. my bad for not taking it out of the box) the intercooler acted like it didnt want to go in, but after removing the throttle cable from the junction box, it was pretty simple. the intercooler piping was the problem of the night. piecing it together was easy, but having clearance for the hood to close and the BOV to not touch the cold pipe wasnt happening. it was clearly time for another beer. beer number 2 (while working on the car, number 6 for the night) was magical. "lets cloak the turbo" dante says. "word. i should have thought about that 30 minutes ago." but the beer was worth it. so we cloaked the turbo about 2 or 3 inches towards the front of the car.....perfect placement for everything. the intercooler pipes where then installed and ready for boost. after that, we decided to call it a night. our kids were tired and our wives were complaining about us being in the garage all night. (typical women sh*t) so tomorrow is another day and we will be back on the grind. looks like cooling and oil lines followed by vacuum and electrical tomorrow. if its not done by monday, it will definitely be done by next weekend.

07-18-2009, 06:35 PM	#5 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	ok here are some crappy pics. one of the turbo, one of the beautiful tubular manifold hiding under the piping, and one of the whole engine. Attached Thumbnails

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07-18-2009, 11:44 AM	#2 (permalink)
MR2enV WHY SO SERIOUS? Join Date: Mar 2007 Location: Miramar, Florida Posts: 443 Thanks: 0 Thanked 6 Times in 6 Posts iTrader Rating: (3/80% )	im glad to hear your puttin it all together... remember not blowing up is in the tune... gotta pull timing back and get that air fuel on point....

07-18-2009, 12:01 PM	#3 (permalink)
1stgen Yup Join Date: Aug 2008 Location: Central Coast CA Posts: 383 Thanks: 11 Thanked 12 Times in 11 Posts My Google Map iTrader Rating: (1/100% )	pix or it never happened....grats on starting the project. These ones are always fun. I will be starting this if my wife doesnt wreck my 2 while I am gone "on vacation"

07-18-2009, 03:42 PM	#4 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	im gonna take some pics in a little bit and put them up.

07-18-2009, 07:45 PM	#6 (permalink)
1stgen Yup Join Date: Aug 2008 Location: Central Coast CA Posts: 383 Thanks: 11 Thanked 12 Times in 11 Posts My Google Map iTrader Rating: (1/100% )	looks like fun cant wait to try to blow mine up. then ill have room for a v6 :P

07-18-2009, 08:59 PM	#7 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	yeah i was planning on working on it a little more tonight, but i got stuck watching the kids while my wife is at the hospital with her brother. thats one more day without the two. oh well, thats just gonna motivate me to work harder and longer tomorrow.

07-19-2009, 03:46 PM	#8 (permalink)
tylerh86 No Skills Join Date: Jul 2009 Posts: 2 Thanks: 0 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	where did u get the turbo kit from, and what motor do you have

07-19-2009, 08:14 PM	#9 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	i got the kit from forum member cavanagh. the motor is the 1991 stock 2.2l 5sfe n/a motor

07-19-2009, 11:13 PM	#10 (permalink)
killermillermr2 Honda Hunter Join Date: Dec 2007 Location: Colorado Posts: 701 Thanks: 22 Thanked 22 Times in 22 Posts iTrader Rating: (6/100% )	All right man! Your IC piping is ran about the same as mine. I just got that U bend in and my janky original setup out. I found it was easier to get the injectors in and out if you take the valve cover off. Gives your hands way more room and a straight shot at the fuel rail.

07-19-2009, 11:39 PM	#11 (permalink)
MR2enV WHY SO SERIOUS? Join Date: Mar 2007 Location: Miramar, Florida Posts: 443 Thanks: 0 Thanked 6 Times in 6 Posts iTrader Rating: (3/80% )	I would have done a trunk mount intercooler setup.... there would be alot more room in the engine bay.... I hated hoe I had to take out the piping everytime I had to change, replace, or fix something around the pipes...

07-20-2009, 03:07 AM	#12 (permalink)
1stgen Yup Join Date: Aug 2008 Location: Central Coast CA Posts: 383 Thanks: 11 Thanked 12 Times in 11 Posts My Google Map iTrader Rating: (1/100% )	or you could just rig up the intercooler to be on the other side of the car....instead of cutting holes in the trunk. That is how I figure IM going to be routing my piping..all shoved in one corner..

07-20-2009, 09:44 AM	#13 (permalink)
MR2enV WHY SO SERIOUS? Join Date: Mar 2007 Location: Miramar, Florida Posts: 443 Thanks: 0 Thanked 6 Times in 6 Posts iTrader Rating: (3/80% )	yea thats how my setup was.. the intercooler and piping on the driver side vent

07-20-2009, 07:14 PM	#14 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	thats a good looking setup you got

07-20-2009, 09:37 PM	#15 (permalink)
MR2enV WHY SO SERIOUS? Join Date: Mar 2007 Location: Miramar, Florida Posts: 443 Thanks: 0 Thanked 6 Times in 6 Posts iTrader Rating: (3/80% )	nice setup i had to be exact........you have some of it and saintg2000 has the rest

07-21-2009, 12:43 PM	#16 (permalink)
tstoney82 shop bitch Join Date: May 2009 Location: clayton nc Posts: 395 Thanks: 11 Thanked 7 Times in 7 Posts iTrader Rating: (3/100% )	you are also running a 2.0. ive got the good old 2.2. my intake manifold would probably allow for more space on the drivers side if i had that setup, but the setup i have is good for now. i wasnt really in the mood to custom make brakets or anything.

07-21-2009, 10:47 PM	#17 (permalink)
killermillermr2 Honda Hunter Join Date: Dec 2007 Location: Colorado Posts: 701 Thanks: 22 Thanked 22 Times in 22 Posts iTrader Rating: (6/100% )	I thought this might be a better place to answer your question. Are you talking about the down pipe?

07-22-2009, 12:19 AM	#19 (permalink)
killermillermr2 Honda Hunter Join Date: Dec 2007 Location: Colorado Posts: 701 Thanks: 22 Thanked 22 Times in 22 Posts iTrader Rating: (6/100% )	^ I was wondering when you were going to pipe in with that

07-22-2009, 12:52 AM	#20 (permalink)
YELLOW_MR2 5SFTE Powered! Join Date: Nov 2008 Location: Washington St Posts: 1,092 Thanks: 94 Thanked 23 Times in 21 Posts iTrader Rating: (4/100% )	LOL its been piped in for a long time.