2007 Turbo Build Thread - Page 3 - Saturn Sky Forums: Saturn Sky Forum
Saturn Sky Performance Discussion Internal Engine | External Engine | Suspension | Exhaust | Upgrades and Aftermarket

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post #31 of 49 (permalink) Old 01-02-2019, 01:54 PM Thread Starter
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More updates! Drilled out my oil return boss the other day! In the instructions it says to install the new thermostat housing and water pipe before drilling the hole, however I would drill the hole with those removed as there was much more room to work with then off. It took a while because I wasn’t sure how deep the hold was going to be so I was packing grease onto the drill bit every few mm to catch shavings (I mean packed I used nearly 1 lb of grease). Also when pulling the drill bit out I would use a shop vacuum to keep any shavings from falling thru the hole. After drilling the hole I used a gun cleaning kit with a dab of grease on the end to surgically remove a few shavings in the pan I could see thru the oil return hole. After I was satisfied and didn’t see any shavings I flushed the oil pan. The first 2 quarts I ran thru the oil return did have some tiny metal specs but no shavings. After a second flush the oil had no visible metal in it. I feel overall pretty good about the drilling job.

Next up was to install the new thermostat housing, water tube, downpipe and exhaust manifold. I figured installing the manifold and downpipe first might make the turbo line up easier. I did go out to the autoparts store and bought some heat wrap for the downpipe and my screamer pipe off the wastegate. Also some more wrap for electronics and lines near the hot stuff. Wrapped all those lines and wires up before dropping the downpipe in. Had a little bit of a though time getting things to line up there but it worked out. Got to do a test fit of the turbo and realized taking an angle grinder to the Power Steering reservoir bracket would give us more room to work. I know they sell relocation kits for this but cutting was free. Today I’m going to be dropping the turbo in but I’ll have to figure out how to mount the wastegate so my screamer pipe will fit. Also I will have to go buy more **** from the autoparts store since the vacuum line coming from my compressor housing is entirely too short to run to the banjo bolt on my wastegate LOL. The instructions also do not include anything about orientation or when in the process you should even attempt to mount the wastegate so if anyone has a PAW turbo with an open dump please let me know how mine should be oriented or include any pics if you can. I quit last night because I was getting pissed off trying to figure it out.

More updates to come. Should be wrapping this up soon once Dave @ PAW gets me my new tune and I wrap the install up.
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post #32 of 49 (permalink) Old 01-02-2019, 02:03 PM Thread Starter
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Robo,

I don’t think those hoses have came off since they were put on at the factory. Lol

also another thing I found when removing my old thermostat housing was the cause of my P0128 code. My thermostat was toast (glad I got a new one). It would work intermittently but would never really display temps that seemed correct so I figured my Tstat was bad. The seal that has been blown off on the old thermostat was rubber. On the new design from ACdelco they have replaced this seal with metal. I don’t think I will have any issues with the new unit failing.
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post #33 of 49 (permalink) Old 01-05-2019, 08:14 PM Thread Starter
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Today was the day! We finished everything up at 4 am this morning and got it tuned and running! I am running a bit rich on idle as well as my engine temps are a little high (to be expected with the addition of a turbo I suppose). Stayed at around 200-220 During the test drive. BOY DOES SHE SOUND MEAN NOW. I love the open dump wastegate and bov. Even driving like a grandpa and not hitting positive boost it still sneezes on the throttle let off. So far I’m in love. Couple of snags along the way but I’m glad I took the time to do it myself. Definitely a proud moment.

I’m sorry there was a few days I didn’t post updates. I wrote out a great big long post yesterday night to update everyone w pics and what have you but as I was about to post it signeed me out of the forum and deleted the post so I just said hell with it and went to bed. If anybody’s got any questions about stuff I did or the process feel free to ask.

Anyways, here’s some pics! Last one was just before install
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post #34 of 49 (permalink) Old 01-06-2019, 01:04 AM
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Today was the day!
I haven't been jealous of anyone or anything for a long time... until now.

That looks sick.

Perfect job.
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post #35 of 49 (permalink) Old 01-06-2019, 11:33 PM Thread Starter
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Thanks parakeetjohn! I appreciate it man!

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post #36 of 49 (permalink) Old 01-07-2019, 02:10 PM
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Good work sir. You're going to love it.


V.A.L. (#1108)
2007 2.4 Base
MagnaFlow dual outlet, quad tip exhaust test car
**Sold**

Max (#1547)
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Too much to list here. See my Garage for details.
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post #37 of 49 (permalink) Old 01-07-2019, 03:12 PM Thread Starter
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Robo,

Im running on just the base map until the second iteration of the tune is emailed.. but for now, im loving it. Boost is exactly what this car needs! and the open dump wastegate and bov from tial sound great too. my smiles per mile are through the roof. Maybe i dont even need to fix my radio when im just listening to the car haha. i havent got to really test it, im not going to WOT or really get on it until i get the tune complete but ill post something here once i do get to test it.

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post #38 of 49 (permalink) Old 01-07-2019, 05:16 PM
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Best to just take it easy until the tuner tells you to do some wide open runs, that's smart.

But yea, even on just a few psi the car really wakes up. I don't have an open waste gate dump...even in my new build as I want a lower profile...but I'm debating getting a BOV and seeing how that sounds...the recirculating valve is already pretty loud.


V.A.L. (#1108)
2007 2.4 Base
MagnaFlow dual outlet, quad tip exhaust test car
**Sold**

Max (#1547)
2007 TURBO 2.4
Too much to list here. See my Garage for details.
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post #39 of 49 (permalink) Old 01-07-2019, 09:52 PM
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Best to just take it easy until the tuner tells you to do some wide open runs, that's smart. [IMG class=inlineimg]/forums/images/smilies/biggrin2.gif[/IMG]

But yea, even on just a few psi the car really wakes up. I don't have an open waste gate dump...even in my new build as I want a lower profile...but I'm debating getting a BOV and seeing how that sounds...the recirculating valve is already pretty loud.
I need to get my 2007 a bit louder/deeper. That ping-ping-ping per second on the 2007 heard regarding that compression injector whatever is all you practically hear at idle. I wonder if anyone found an alternative for that whatever ping injector setup on the 2007's. I wonder if all years were like that.
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post #40 of 49 (permalink) Old 01-07-2019, 10:12 PM Thread Starter
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ParakeetJohn,

What exhaust do you have? I put a solo performance high flow cat and catback on mine when it was NA and it really livened up the sound.

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post #41 of 49 (permalink) Old 01-08-2019, 03:05 AM
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ParakeetJohn,

What exhaust do you have? I put a solo performance high flow cat and catback on mine when it was NA and it really livened up the sound.
I have the RL Stock exhaust I believed
... dual exhaust pipes, black rectangles.

I like the look of those black tips.

Any preferences on the deepest growl I can get... performance benefit wouldn't hurt.

Thank's.
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post #42 of 49 (permalink) Old 01-08-2019, 08:35 AM Thread Starter
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That would be it! You may be able to get some performance gains (maybe 10 hp) since you have the redline out of a higher flowing exhaust.

i noticed this post just last night on the Solstice forums:
"I have a good condition magnaflow 3" exhaust system for sale off of a 2007 GXP (2.0T). I sold the car and no longer need it. Car came with it equipped at 27k miles and I took it off after only 5k'ish miles when I installed a solo cat back (too loud for me). Based on what the guy said who sold me the car, I doubt the system has more then 20k miles on it (not that that matters). Asking $400 OBO local pickups only located just NW of Atlanta off of I75." and its being bumped for sale

From what i have gathered on here solo performance seems to have louder exhaust system than the magnaflow and both are louder than stock. also if you really want that growl id recommend a high flow cat too. It made a noticeable difference for mine. Also the guys over at solo are really good and if you gave them a call im sure they could assist you in finding exactly what youre looking for.

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post #43 of 49 (permalink) Old 01-09-2019, 01:33 AM
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... also if you really want that growl id recommend a high flow cat too. It made a noticeable difference for mine. Also the guys over at solo are really good and if you gave them a call im sure they could assist you in finding exactly what youre looking for.
Humm... sounds perfect. Any issues passing smog with the setup?

I'm in the San Diego Diego... I wonder who has experience working on our cars out here.... exhaust and such.
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post #44 of 49 (permalink) Old 01-09-2019, 10:00 AM Thread Starter
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Humm... sounds perfect. Any issues passing smog with the setup?
Good Question.. Im in KY. No smog testing.

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post #45 of 49 (permalink) Old 01-09-2019, 11:33 AM
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Humm... sounds perfect. Any issues passing smog with the setup?

I'm in the San Diego Diego... I wonder who has experience working on our cars out here.... exhaust and such.
So here is the deal.

BY LAW in CA, you cannot change your stock cat unless it is damaged and non-functional. Thus if yours is working no reputable shop will touch that stock cat.

If it is non-functional...say somehow a screwdriver punctured the cat in some way...you can only replace it with a NEW CARB approved cat. For our cars, the only CARB approved cat is the OEM cat. This means that even if your cat is damaged you must replace it with a new OEM cat...you can't even replace it with a used OEM cat off a damaged car.

Now, if you replace your cat anyway with something like the Solo high flow cat, there is a chance that when you go to smog the car the smog tech will have no idea if your cat is OEM or not. The high flow cats will pass a sniffer test but since they do not have CARB certification they technically are not legal and would fail the visual part of the inspection IF noticed.

As for the exhaust from the cat back, that's still legal but I would definitely go with someone who is a big name brand exhaust company like MagnaFlow or Borlla. The reason I mention this is as of January 1st of this year, if you receive a ticket for a modified exhaust, you can no longer just fix it then pay the $25 fee for a fixed infraction. Now you have to fix the exhaust AND pay the full fine of the ticket which I'm hearing (and still need to get verification because it seems excessive) can be up to $1,000. I know my MagnaFlow exhaust meets the state requirement of 95 db under their testing standards and hence why I run it. If I get cited, I can take it to a ref station and have it certified if need be.

For installing the exhaust, it is pretty easy. Jack up the car, pull the plug on the O2 sensor, pull off the four hangers that hold on the exhaust, and then undo the two bolts that attach the exhaust up front. Putting on a MagnaFlow is a bit more difficult since you have to assemble the pieces of the pipe and clamp them together as you install it. Still, not hard.


V.A.L. (#1108)
2007 2.4 Base
MagnaFlow dual outlet, quad tip exhaust test car
**Sold**

Max (#1547)
2007 TURBO 2.4
Too much to list here. See my Garage for details.
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