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Discussion Starter #1 (Edited)
UPDATE: Due to a PCM failure, this build will be postponed. I'm hoping to make it on November 21-22nd. More details in a new post later on.

NEW DATE: November 21-22nd.

Now I'm calling it a mod day but most mod days a bunch of people work on their cars. This mod day is going to be a little different. I will be installing and tuning the LE5 turbo build and probably will not have time to help out with any other mods. Also, the garage I'll be doing it in is my Girlfriend's and we don't have a lot of parking at her place to load up with cars to be worked on. It's a two car garage and really only has room to work on one car.

Now I'm not asking for help. I can do this build solo (really isn't going to be all that hard) but I know there are some people on here who would like to learn more about our cars and since this is an LNF turbo setup going on an LE5, there will be something for both Redline owners and NA owners to learn about. If you want to watch and see how this is done, Cool. If you want to jump in and lend a hand with some of the processes, it would help out. If you don't mind making a couple trips to Autozone (There are ALWAYS things you need at Autozone at a build day) I'd REALLY appreciate it.

Some of the tasks we will be performing for this build:

Coolant change
Oil change
Exhaust manifold removal
2.4 LE5 injector replacement
LE5 fuel system depressurization
LNF exhaust manifold, turbo, and cat installation including water and oil lines
Charge pipe installation
Boost controller installation
LE5 2 bar MAP installation
Oil Catch Can installation
Air intake basic fabrication and installation
Ecotech tuning with HDtuners

I suspect that most of the build part will only take place on Saturday. It really shouldn't take more than a day to put the turbo on. (Intercooler and water pipe/thermostat housing are already done.) Sunday will mostly be tuning and getting her running right. We'll order pizza for lunch and I'll have some cold ones on hand for those that want to show up.
 

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Some how when I read this, I think of Tom Sawyer and Huck Finn, a long white fence and perfection painting.:jester:
 

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Discussion Starter #3
LOL RtE. Great thing is my GF keeps her place spotless all the time anyway. I try to pick up after myself best as I can but I'll be honest, my level of "clean" when it comes to the house is far lower than hers. LOL
 

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mind if I tag along just got a 07 sky, im a newbie on stuff like this and would like to learn more ! i will bring some booze if its allowed? any req?
 

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Discussion Starter #5
Booze isn't just allowed, it is almost a requirement. LOL But no driving if you've been drinking! That's mandatory! (At mod days we don't take your keys, you just come out to find your car on jack stands.) LOL

I would keep the alcohol to beer though. Really the hard stuff tends to get a little out of control and that's not a good combo when wrenching.

Shoot me a PM and I can send you details.
 

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Darned east coast whimps!!!

I will make the 7th. No interest in the tuning stuff, but would not mind helping put the thing together.
 

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Discussion Starter #11
Alright folks, if you want to participate in the build I'd suggest getting to the location I sent you folks by about 10 am. I'll be up before that but plan on making an Autozone/Pepboys run early in the morning to collect some last minute supplies/tools. I should be back and ready to wrench by 10 am.

We'll also be making another run to PepBoys later on in the day once I figure out what we'll need to fabricate a cold air intake for this build. Really can't figure that out until the turbo is on the car otherwise I'd already have that setup. Will be going over my inventory this weekend and getting a final supplies list together. (Things like a proper claw wrench for the oil filter cap, oil, filter, coolant, etc.)
 

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Alright folks, if you want to participate in the build I'd suggest getting to the location I sent you folks by about 10 am. I'll be up before that but plan on making an Autozone/Pepboys run early in the morning to collect some last minute supplies/tools. I should be back and ready to wrench by 10 am.

We'll also be making another run to PepBoys later on in the day once I figure out what we'll need to fabricate a cold air intake for this build. Really can't figure that out until the turbo is on the car otherwise I'd already have that setup. Will be going over my inventory this weekend and getting a final supplies list together. (Things like a proper claw wrench for the oil filter cap, oil, filter, coolant, etc.)
"Claw Wrench"? What about a "shorty" 32 mm socket? About $8 at O'Reilly's IIRC.

Yogi
 

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Discussion Starter #13 (Edited)
I'll have to look for one...the last 32 mm socket I got wouldn't clear the head/block above it when it was on.

Claw wrench (also called a crows foot wrench):


Though I do like the shorty socket idea better. Autozone has them for under $10.
 

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I'll have to look for one...the last 32 mm socket I got wouldn't clear the head/block above it. when it was on.

Claw wrench (also called a crows foot wrench):
OK. Now I see. Thanks for the pick.

The 32mm shorty will work. Look for it in the oil change section. I believe that mine is made by "Lisle".

Found it: Lisle Corporation
 

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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
 

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Discussion Starter #17 (Edited)
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. :D Who knew this is where I'd be 9 years later...
 

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Discussion Starter #19
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.

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.
 

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Discussion Starter #20 (Edited)
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.
 
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