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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.
 

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Discussion Starter #23
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.
 

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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! :thumbs:
 

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Discussion Starter #25
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.
 

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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? :dunno:
OK - Thanks will be on the look out for the pic's!
 

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Discussion Starter #27
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.
 

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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?
 

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Not making the Petco show, may make the Sunday one though Robo.

Have to move a tractor in the morning, do a tower site survey in Auanga, and sign paper work on the new toy.
 

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Discussion Starter #34
Last of the parts are coming in...well...the new parts I decided to add that is...and we are still going to do this in just over a week. If anyone who wants to go need directions, pm me. About 75 steps total for the build but defiantly doable in the one day and tuning the next. This is going to be next weekend, 21 and 22 November.
 

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Discussion Starter #35
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.
Just a refresher on what all we will be doing...
 

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He (Tom, I mean Robo) is using this story to get us to his girlfriends house to paint the long white fence around her property. Well that is what I think of every time I read the thread. Should be an interesting day either way. Looking forward to it.
 

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Discussion Starter #37 (Edited)
Honestly I get the Tom Sawyer reference but it isn't like that at all. I don't want others to do my work. As a matter of fact, I doubt more than just a few people will be touching the car at any one time and I will ALWAYS be at least one of those people. Believe me, you have no idea how short the list is of people who, when they put a wrench to my car, don't give me a massive panic attack. It's nothing personal, it just is the way it is.

What I have planned is two "zones" of the build basically. The Driver's side zone and the Passenger's side zone. The only other area of the build would be under the car but that's some pretty simple stuff...unbolting exhaust, draining the oil and then draining the coolant.

The driver's side tasks are fairly straightforward. Remove old intake, swap out injectors and MAP, splice into brake vacuum line for bypass valve actuator, begin the routing of the catch can lines, and installing cold pipe.

The passenger side tasks are more complex. Removal of NA manifold and cat, installation of water and oil lines for turbo, installation of turbo, manifold and turbo cat, routing of catch can lines, routing of bypass valve vac line, installation of hot pipe, boost controller routing and mounting, and fabrication/installation of intake.

I figure I'll be on the passenger side most of the time but will definitely supervise the injector installation. Important not to rip the O-rings on that one.

So, for this build I had the following folks coming:

Gabes Redline
Razz
ThreeFiddy
Skersfan
kohhep

You guys still in? Also I know jgasser was out due to a scheduling conflict but hopefully he's able to attend too. If you guys can confirm here or give me a PM to confirm I'd appreciate it.

This is worse than Christmas as a kid. Excited to have it be just a few days away.
 

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I have run into a problem. As you know I sold my dually to pay for the motorhome. The gentleman wants to pick it up Saturday at noon. I have no choice in the matter. So I may make it down late, or be forced into watching you do your geekiness on Sunday. I prefer pickin and an grinnin, over tunin. Anyway wanted to let you know, I was just notified he would be here Saturday at noon.
 
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