I NEED Boost... Opinions puh-lease

[Focus_Sh1ft]

Originally Posted by Yoda

can't wait to see you mount it up

Same here bro

I wasn't expecting to get a water cooled turbo, and I just got back from getting bolts to close the holes... I'll make a trip to home depot again early tomorrow and grab some nipples + lines to get it water cooled. Where would be the best place to tap the coolant lines?

[pimp my yaris]

I see your making big moves, the race is on. Chi-town vs. Jerezy

[Focus_Sh1ft]

Originally Posted by pimp my yaris

I see your making big moves, the race is on. Chi-town vs. Jerezy

BRIIIING IT

I'll let you know that, despite what you may see on Jersey Shore, I am not a drunken and obnoxious waste of life and am capable of being productive.

So far I'm thinking I'll use the TB coolant lines along with a tee to cool the turbo.

[Bluevitz-rs]

Originally Posted by Focus_Sh1ft

Reversed MAF wires and now the engine runs
Still have a CEL though... Gonna get the code read later.

Did you pull the EFI fuse to clear the codes? And does it come on as soon as you start the car, or after it's been running for a while?

PS, you're welcome

[Focus_Sh1ft]

Exhaust is done and is LOUD, especially in the cabin. I'm gonna order some Dynamat, otherwise it's great

Here' some pictures of the illusive Zage kit to hold you guys over.




And here's about half the additional stuff I bought that is needed for oil / water feed and return attachment, as well as others. Gonna throw the specs here that will be put in my future install guide:

2x 7/16" x 1 1/4" bolts (turbo)*
2x M8-1.25 x 40mm bolts (intercooler, could be shorter)
2x 1/8" x close fittings (oil feed+return)**
1x 3/8" female to 1/8" NPT female fitting (oil feed)
1x 1/2" male flare connector (extend feed line)***
2x 1/4" compression male to 1/4" NPT fitting (water, turbo outlets)
2x 1/4" NPT male to 1/4" barb (water... 5/16" couldn't be found)
3x 5/16" nylon tees (cooling turbo, BOV)
2x 5/16" dia. coolant tubing (turbo)
1x 5/16" dia. vacuum hose (BOV)
1x 1/2" fitting, 36" steel gas hose (oil feed, was all I could find, praying it works...)***

*Only need if water cooling isn't used.
**I wanted to use a 1/8" x 1 1/4" Nipple for the return fitting that gets welded into the block, but the threading appears to be problematic with the threaded tee in the Zage kit. I'll probably just use the 1/8" x close fitting. Shorter, but should work.
***Shouldn't actually be needed.



Also would like to mention that my CEL, once again, disappeared on its own.

[Focus_Sh1ft]

Lemme also add what I now know about this kit after looking it over carefully.

-There are no bolts to attach the intercooler
-If using a sandwich adapter to feed the turbo, some adapters nuts will be needed
-I don't know what they expect you to do with the feed tbh. I think that's up to the user, but the amount of steel braided line included won't be getting you anywhere. *I had the lines mixed up. This shouldn't be a problem.
-The BOV has a bypass, but 1/4" rubber hosing is (obviously) needed but not included. A plug is included to close the bypass (but using the BOV and not the bypass is stupid).
-The turbo, to my surprise, can be water cooled (which means my turbo timer will only be good for pretty lights ). However, there are no bolts, nipples, or even hoses included to make use of it. In fact, there aren't even additional bolts to close the holes.
-I'm PRETTY SURE the actuator can be adjusted to add/subtract boost.
-The Downpipe has 1 bung for the stock o2, and one with a removable plug.
-The Turbo has 2 welded holes (what could they be used for?).

As you can see, this kit is already far from a full bolt-on (although I don't think Zage ever claimed it to be). However, with some additional stuff and some guidance, it has the potential to be. I had some prior obligations today so I got kind of sidetracked... At this point though, I'm pretty sure all I need is some lines for the coolant. I didn't realize fuel lines wouldn't hold up, as the coolant will eat right through them apparently.

[Nexus1155]

The other port on the downpipe, the picture isn't too clear, but it looks like there is a plug in the other one that can be removed / unscrewed and is not the full size of the bung. Should be able to take it out and put a wideband sensor there.

The plugs on the turbo are usually secondary coolant locations for the feed i beleive, my K04s come with one on the side, depending on where I get the turbo, I need to swap the plug to the other one.

Some things that aren't included in the kit seem just a minor inconvenience as long as everything else bolts up.

Cracking pressure is cracking pressure you can make it harder to open to increase tension on the rod, but spring rate is spring rate inside the actuator housing itself. Use a boost controller if you want to raise boost the way it is setup now is so it opens with cracking pressure. probably preset anywhere from 6-10psi.

[cali yaris]

Why in the world would they weld the 2nd bung shut, instead of threading an insert into it?

Otherwise, not too bad so far! Keep going!

[Focus_Sh1ft]

Sorry guys, you're right, I totally missed it. The second bung on the downpipe has a removable plug. The turbo though... I still don't think the plugs are removable, but I guess it's irrelevant.

[Focus_Sh1ft]

Here's day one of the install. I got stuck A LOT... but only because I lacked the necessary tools. Hoping tomorrow will be slightly more productive.

Engine Before Pics


Pics of everything being installed to the Turbo


Exhaust Manifold + o2 sensor



And now, here's two reasons I believe Zage has been known for exploding turbos.

Basically, the above bolt goes into the oil feed spot on the turbo, and the bolt in the second picture has a loop on the end that goes around the first bolt. They both have little holes drilled in them that allow the oil through (sorry no pictures, wish I had). I personally think it's a crummy design and could very well be problematic. The only plus is that the feed adapter can be adjusted slightly, but what for? A simple elbow would have sufficed...

Here's my current snag. I have everything attached to the turbo, such that I can mount it up to the engine block and then run the lines to the appropriate places. However, and I dare say, this may be where the alleged "fitment issue" comes into play. There's no way in hell I can fit this thing in (and don't say take everything off because the difference will be minimal). I removed the fuel hose, and thought I could move the AC lines. A ton of air/gas spewed out and I couldn't stop it by rebolting it. COULD ANYONE CLARIFY WHAT THIS WAS? I believe it was just compressed air, but I know little regarding AC lines. Basically, once it's in it won't be a problem. But the AC lines are REALLY in the way currently.

[coheed]

What came out of your Ac lines was R134a, and actually since its escaped the lines your a criminal. Its illegal to vent it into free air( ie not into a container). But I wont report you cause you didnt know. lol Now your ac wont work until you recharge it and maybe replace a few seals.

But on the bright side, if you can remove the lines from the engine bay you wont cause anymore harm to the ac system. And if you can remove the lines you hopefully wont have anymore clearance issues.

Edit: I was just messin bout the criminal thing. Wanted to clarify that before it could get out of hand. It is illegal but I cant say I havent done it myself.

[Nexus1155]

It was most likely freon, I hope you stepped away and didn't breathe any in. It is known to be harmful and cause cancer in some studies.

You are right, that Oil feed looks a little weird and there should be a better way, but that will work.

You look like you are making good progress, keep it going!.

If you are having fitment issues, I would just try to fit the turbo and manifold in at once without the downpipe on since you can get that in later, it may allow for easier rotationability that would help you out squeezing it in there?

You also may need to reclock the turbo, atleast the cold side since you manage where your lines are going. I can't see how that one reclocks but most likely if theres no bolts or collar theres a C Clip in there.

You can always take a couple of pliers and add force to bend the lines out the way a little bit, or just run no AC :P I dunno what the temps were in Jersey this year.

MORE PICS!

[coheed]

Quick question. Is the zage kit cheaper then piecing it together? Wanting to go turbo soon and trying to make a plan.

[Focus_Sh1ft]

Originally Posted by coheed

What came out of your Ac lines was R134a

I figured it was the AC coolant, but was confused because it didn't burn... Nor did I die

Any info on how to recharge this and seal it? I couldn't figure out how to close the leak, and I didn't see any o-rings or gaskets on the lines. I would like to use the AC again sometime soon though lol.

On the plus side, I think I'll make the best of a somewhat crappy situation and tear those suckers out temporarily to give me the needed clearance.

Nexus, I was toying with the idea of pulling the downpipe off, but I believe it's going to be near impossible to bolt it on once it's in the engine. If the above doesn't work, that'll be next though.

Oh and coheed, I'm not entirely sure which is cheaper. I can tell you right now the Zage kit runs at $1800 and, so far, has only needed some additional bolts and brass fittings. I think pimp my yaris is up to nearly $1000 on his custom install and still has a couple things left to buy. Keep a close eye on the two of us

[coheed]

Your local Autozone should carry a recharge/ sealant kit for under $30. Me and a buddy just did his integra in his front yard with no tools. Really easy to do.

And you are an inspiration to me. i want to do this to mine so bad but have no funds right now.

[Focus_Sh1ft]

Originally Posted by coheed

Your local Autozone should carry a recharge/ sealant kit for under $30. Me and a buddy just did his integra in his front yard with no tools. Really easy to do.

And you are an inspiration to me. i want to do this to mine so bad but have no funds right now.

Thanks a bunch man. I just looked it up as well and it looks easy peesy. Just gotta figure out how to reseal where it leaked out... I'm thinking a man by the name of Mr. J.B Weld might just have a solution for me

And thanks even more for the vote of confidence, I feel a little beat up after today lol. Not having the right tools sucks, but that's sorted out now. I barely had the funds to do this and was hesitant because turbocharging this car is, for the most part, still a mystery.

Methinks you should keep your pants on for the time being, and be the first user of my ultimate Zage turbo install guide. It's already in the works
It's going to have pre-install installs as well, such as the FIC, Apexi turbo timer, gauges, and whatever else I think of. I'd be pretty happy to get this car to be a little more popular in the forced induction category (or atleast recognized by tuning / exhaust shops lol).

Originally Posted by Nexus1155

You also may need to reclock the turbo

I get the concept... I think, but shouldn't this have been done out of factory? Are you saying I should check it just to be safe?

[Nexus1155]

I'm just saying that because I don't know where you are getting stuck with it or where you are going to have the charge piping run. You always want things facing the easiest way

[coheed]

Originally Posted by Focus_Sh1ft

Methinks you should keep your pants on for the time being, and be the first user of my ultimate Zage turbo install guide. It's already in the works
It's going to have pre-install installs as well, such as the FIC, Apexi turbo timer, gauges, and whatever else I think of. I'd be pretty happy to get this car to be a little more popular in the forced induction category (or atleast recognized by tuning / exhaust shops lol).

I think I am gonna go this route. The way I was thinking previously was piecing it. But that would've included a cheapo ebay turbo my friend has. And the zage one being water and oil cooled has pretty much swayed me. But Im also leaning more to eManage ultimate because one of my friends already has the software and some tuning expirience with it.