NEW DATE! So Cal Mod Day - LE5 Turbo Build - Page 2 - Saturn Sky Forums: Saturn Sky Forum
Pacific California | Idaho | Nevada | Oregon | Washington | Hawaii | Alaska

User Tag List

Reply
 
LinkBack Thread Tools Display Modes
post #16 of 106 (permalink) Old 10-29-2015, 04:43 PM
Senior Member
 
Join Date: Feb 2010
Location: League City, TX (Houston)
Posts: 2,058
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 68 Post(s)
Quote:
Originally Posted by Robotech View Post
I want to get a set of those wrenches anyway (they can come in handy) but for this build that shorty socket will be perfect.
Have fun!

Yogi

"Black Bart"
2008 Onyx Black Redline with Black Convertible Top
5 Speed Stick
Single Disk Monsoon Sound
Black Interior with Black Leather Seats
GM MB-222 Chrome "Snowflake" Wheels
Yogi is offline  
post #17 of 106 (permalink) Old 10-29-2015, 05:50 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
You have no idea. I don't think I've been this excited for a day to arrive since I knew my Whipple was coming for the Grand Prix!

That was pretty bad...



Yes, I was waiting by my front door with a camera to take a picture of the FedEx guy carrying it to my door. (Remember, this was before smart phones were really main stream.) Long story on that one.

That said though, this was a project I wanted to do when I got my FIRST Sky back in 06! That I didn't do because I was doing this project. Then, when I bought this Sky and got to test drive a GXP at the same dealership, I reminded myself I could always add a turbo to the 2.4 Sky so from the day I got this car I had this build in mind...

...a year and a half later, you might say I'm a bit excited and, I PROMISE, I'll be having a blast! "Wish you were here!" <Insert cheesy So Cal Beach Post Card photo here>

EDIT: Okay, funny tie in here...in a couple ways. So that above picture wasn't the only one I took that day...



Inspect contents immediately?! OKAY!



Now, the eagle eyes among you may notice a little black box in that last picture with a Saturn logo on it. That was a little 1mb thumb drive that GM sent out to prospective Sky buyers that had some marketing material on it. You could, of course, delete that then use the thumb drive to your heart's content. Under it you'll see an IBM Thinkpad laptop. Those suckers were tanks and really durable. I used that as my tuning PC for the Grand Prix for it's durability...

...It has HPTuners on it now and I'm getting it set up to tune the Sky on the 8th. Who knew this is where I'd be 9 years later...


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.

Last edited by Robotech; 10-29-2015 at 05:57 PM.
Robotech is offline  
post #18 of 106 (permalink) Old 10-29-2015, 07:01 PM
Member
 
Join Date: Oct 2015
Location: Torrance CA
Posts: 44
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Early Christmas gift lol !
ThreeFiddy is offline  
post #19 of 106 (permalink) Old 11-02-2015, 01:26 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
The build is postponed...thinking November 21-22nd. Here is the why.

This Saturday I took the Sky out to run an errand or two and got a check engine light. I scanned and the only code I got was a P0606. Looked that up because that's a new one on me.

Quote:
As a vehicle owner there is little you can do to fix this code. The most common fix for a P0606 code is to replace the PCM, although in some cases re-flashing the PCM with updated software could possibly fix this. Be sure to check for TSB's on your vehicle (Technical Service Bulletins).

In all likelyhood the fix is to replace the PCM. This is generally not a "do-it-yourself" task, although in some cases it may be. We strongly recommend you have a qualified repair shop / technician do the work, one that has the capability to reprogram the new PCM. Installing the new PCM may involve using special tools to program the vehicle's VIN (vehicle identification number) and/or anti-theft information (PATS, etc.).
So she needs to go into the dealer and have this looked at. Just a reflash is $110 so this will be $100 and covered under my powertrain warranty. However, if I need a new ECM, it could take 4-5 days for them to receive it. So, while I MIGHT be able to get this done by the weekend, I'm going to day I doubt it...and even if I do, it's going to make funds tight for the build. So I'm going to postpone it for two weeks and that should give me enough time to get this resolved.

What lousy timing though.


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.
Robotech is offline  
post #20 of 106 (permalink) Old 11-04-2015, 04:05 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
So some have asked, what EXACTLY will we be doing on this build? Well, here is the checklist. Now mind you, this isn't totally detailed. For instance, it says: "Locate appropriate place for Oil Catch Can between breather line and turbo." and "Mount oil catch can." Sounds basic but what it doesn't say is we're going to need to drill holes for the screws for the can and have it placed where the inlet and outlet point to the correct sides of the engine bay. So take the following list as a short checklist of tasks.

Also, there are a couple diagrams I have that will be on this checklist when I post it in the garage such as how to route the lines for the manual boost controller and the proper torque sequence for the exhaust manifold bolts.

Now, if anyone has anything I have left out, need to add, need to clarify, please feel free to let me know here on this thread so I can update the checklist.

1. Jack up car and secure on jack stands.
2. Unplug negative terminal from battery.
3. Unplug MAF sensor from harness.
4. Remove stock intake.
5. Unplug both O2 sensors from harness. Remove 2 bolts holding exhaust to catalytic converter.
6. Loosen oil cap and drain oil. Replace oil plug when done. Change oil filter.
7. Loosen coolant overflow cap. Drain coolant. Close drain when done.
8. Remove exhaust manifold heat shield.
9. Remove exhaust manifold bolts. Remove catalytic converter if necessary to access all bolts.
10. Remove exhaust (and catalytic converter if not removed in previous step) from car.
11. Remove plug from thermostat housing for turbo water line.
12. Remove middle oil plug from block for turbo oil line.
13. Remove front water pump drive chain cover from front of engine.
14. Install stud into block for turbo charger brace.
15. Hook up turbo water line to thermostat. Make sure black washers are in place.
16. Hook up turbo oil line to engine block. Make sure black washers are in place.
17. Install new manifold gasket.
18. Install new manifold. Tighten bolts in sequence. Torque to 10 ft/lbs
19. Install exhaust manifold heat shield. Tighten bolts to 18 ft/lbs.
20. Install turbo to manifold. Tighten bolts to 22 ft/lbs.
21. Install water line, water return line, and oil feed line to turbo. Torque to 15 ft/lbs.
22. Modify front plate gasket for oil return line. Run small bead of RTV around hole.
23. Install front plate with nipple for oil return line to front of engine. Torque to 89 in/lbs.
24. Install oil return line on turbo to front plate.
25. Cut upper radiator hose to install water T-fitting for water return on turbo.
26. Install T-fitting into radiator line.
27. Install hose and reducer then connect to turbo water return line.
28. Remove O2 sensor from NA cat and install into new bung on turbo cat.
29. Install Wide Band O2 sensor into stock O2 bung on turbo cat.
30. Install cat to the turbo. Torque nuts to 43 ft/lbs
31. Install exhaust to cat. Torque nuts to 13 ft/lbs
32. Torque catalytic converter brace bracket bolt to 16 ft/lbs. (not sure what this is or where it is)
33. Connect O2 sensors to harnesses.
34. Connect turbo charger brace and tighten bolts to 37 ft/lbs.
35. Unplug and remove stock MAP sensor and install new 2-bar MAP sensor.
36. Remove brake booster vacuum line from intake manifold below Throttle Body.
37. Splice brake booster line. Install 3/8” x 3/8” x ¼” Tee fitting.
38. Run 3/16” vacuum line from tee fitting to Bypass Valve on turbo.
39. Find mounting location for boost controller near turbo.
40. Set boost controller to lowest setting.
41. Bypass N75 waste gate solenoid on turbo with boost controller.
42. Cap off N75 ports with vacuum caps.
43. Depressurize fuel rail.
44. Remove connectors from stock injectors.
45. Remove fuel rail from injectors.
46. Replace injectors with 60# units.
47. Replace fuel rail and tighten bolts to 16 ft/lbs.
48. Attach connectors to new injectors.
49. Remove plugs from intercooler connectors (Intercooler already installed on car).
50. Assemble and install hot side charge pipe between turbo and intercooler. Tighten clamps.
51. Remove MAF sensor from stock intake and install into cold side charge pipe.
52. Install cold side charge pipe between intercooler and throttle body. Tighten clamps.
53. Plug in MAF.
54. Remove stock breather line from valve cover. Replace with longer ½” heater/oil/vacuum line.
55. Locate appropriate place for Oil Catch Can between breather line and turbo.
56. Mount oil catch can.
57. Run ½” line from valve cover to Oil Catch Can input. Cut for appropriate routing.
58. Run 3/8” line from output of Oil Catch Can to nipple on turbo inlet. Cut and route appropriately.
59. Install 45 degree boot onto intake of turbo.
60. Test fit with spare 2.5” pipe to figure out proper routing for turbo intake.
61. Acquire 3” aluminum pipe and a 3” cone air filter from auto parts store based on test fit.
62. Modify and install intake pipe as necessary for fitment. Install intake.
63. Double check all hose clamps for tightness.
64. Refill oil. Secure oil cap.
65. Refill coolant. Bleed system per DDM’s bleed instructions. Secure overflow cap.
66. Reconnect negative terminal on battery.
67. Download stock tune from ECM using HPtuners.
68. Install new tune to ECM using HPTuners.
69. Test start car.
70. Make adjustments to tune for idle as necessary.
71. Check turbo system for oil leaks, water leaks, and air leaks.
72. Triple check all fittings, clamps, and connections.
73. Lower car to the ground.
74. Drive and tune car until satisfactory.


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.

Last edited by Robotech; 11-04-2015 at 07:32 PM.
Robotech is offline  
post #21 of 106 (permalink) Old 11-04-2015, 09:15 PM
Senior Member

 
Specter's Avatar
 
Join Date: Apr 2015
Posts: 459
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 30 Post(s)
Garage
Well, I can clearly see you are missing 2 very important steps...

1. Drink beer. Add in between various steps as necessary and appropriate.
2. Sober up from drinking so much beer before driving.
Specter is offline  
post #22 of 106 (permalink) Old 11-04-2015, 09:23 PM
Senior Member

 
MARVIC 1's Avatar
 
Join Date: Aug 2009
Location: Northern East Florida
Posts: 7,014
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 128 Post(s)
Quote:
Originally Posted by Robotech View Post
So some have asked, what EXACTLY will we be doing on this build? Well, here is the checklist.
Robo, Please explain #51
MARVIC 1 is offline  
post #23 of 106 (permalink) Old 11-04-2015, 09:34 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
The 2.4 has the maf sensor in the intake...which sits about where the cold charge pipe sits in the 2.0. We are removing the intake off the throttle body early but leaving the maf installed. It will eventually going into the cold charge pipe. This is how every 2.4 k04 kit i've seen is setup. So step 51...while it could be performed earlier...is taking the maf out of the na cold air intake and reinstalling it in the cold charge pipe.
Robotech is offline  
post #24 of 106 (permalink) Old 11-04-2015, 09:51 PM
Senior Member

 
MARVIC 1's Avatar
 
Join Date: Aug 2009
Location: Northern East Florida
Posts: 7,014
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 128 Post(s)
Quote:
Originally Posted by Robotech View Post
The 2.4 has the maf sensor in the intake...which sits about where the cold charge pipe sits in the 2.0. We are removing the intake off the throttle body early but leaving the maf installed. It will eventually going into the cold charge pipe. This is how every 2.4 k04 kit i've seen is setup. So step 51...while it could be performed earlier...is taking the maf out of the na cold air intake and reinstalling it in the cold charge pipe.
Why can't it go back onto the new intake???
I can't wait to start seeing pictures of your built. Please document your progress here with pictures of your 2.4 turbo setup..
Thanks!
MARVIC 1 is offline  
post #25 of 106 (permalink) Old 11-04-2015, 10:01 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
There is another sensor in the LNF to measure how much air is coming into the engine...the tmap sensor...that the LE5 just doesn't have. Also keeps from having to try and extend the maf plug to the other side of the engine. Not sure why this is done...but figure Dave and Bill know a hell of a lot more on this than I do so I follow their lead.

Will have plenty of guys there to take pictures and planned on sharing.
Robotech is offline  
post #26 of 106 (permalink) Old 11-04-2015, 10:11 PM
Senior Member

 
MARVIC 1's Avatar
 
Join Date: Aug 2009
Location: Northern East Florida
Posts: 7,014
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 128 Post(s)
Quote:
Originally Posted by Robotech View Post
There is another sensor in the LNF to measure how much air is coming into the engine...the tmap sensor...that the LE5 just doesn't have. Also keeps from having to try and extend the maf plug to the other side of the engine. Not sure why this is done...but figure Dave and Bill know a hell of a lot more on this than I do so I follow their lead.

Will have plenty of guys there to take pictures and planned on sharing.
Interisting, would like to know why, could it be for a tuning purpose?
OK - Thanks will be on the look out for the pic's!
MARVIC 1 is offline  
post #27 of 106 (permalink) Old 11-04-2015, 10:42 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
I have ASSuMEd that it has to do with the logic in the ecm for the 2.4 and that it is more important to know the temp of the air going into the engine after compression and intercooling than before.
Robotech is offline  
post #28 of 106 (permalink) Old 11-04-2015, 10:44 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
Oh...and I forgot to edit...the tmap sensor in the LNF cold pipe is to measure temperature not air Mas or pressure. The map in the intake manifold measures pressure...which the LE5 has too.
Robotech is offline  
post #29 of 106 (permalink) Old 11-04-2015, 10:47 PM
Senior Member

 
MARVIC 1's Avatar
 
Join Date: Aug 2009
Location: Northern East Florida
Posts: 7,014
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 128 Post(s)
Quote:
Originally Posted by Robotech View Post
I have ASSuMEd that it has to do with the logic in the ecm for the 2.4 and that it is more important to know the temp of the air going into the engine after compression and intercooling than before.
Ok Thanks, I need to look this up and see if I find any info on it, have you scoped this out in the internet?
MARVIC 1 is offline  
post #30 of 106 (permalink) Old 11-04-2015, 11:30 PM Thread Starter
Super Moderator
 
Robotech's Avatar
 
Join Date: May 2006
Location: Temecula, CA
Posts: 10,614
Mentioned: 64 Post(s)
Tagged: 3 Thread(s)
Quoted: 1671 Post(s)
Garage
Researched more the how than the why.
Robotech is offline  
Reply

  Saturn Sky Forums: Saturn Sky Forum > Clubs, Events & Regional Discussion > Pacific

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Saturn Sky Forums: Saturn Sky Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome