I NEED Boost... Opinions puh-lease

[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.

[pimp my yaris]

I was also not able to install the turbo and manafold in the car as an assembly. A/C lines were in the way as well. I lowered the turbo behind the engine and let it sit on the K-frame. Then I bolted up my manafold and reached around the manafold and lifted the turbo to it. Then slide the tubo onto the studs and bolt it down. It was the only way to get it all in there without removing the A/C lines. It looks like your turbo will attach to mani with bolts. This might make it easier.

[cali yaris]

Are you guys working from above? When we did my first kit, we removed the subframe and worked from below.

[Focus_Sh1ft]

Originally Posted by cali yaris

Are you guys working from above? When we did my first kit, we removed the subframe and worked from below.

Interesting, how hard would that be? Doing this would most likely make it easier to route some of the piping as well.

[cdydjded]

When I installed be kit, 1/2 was done from the top & 1/2 was done from below. I did not have to remove the cowl nor the subframe. Also did not touch the A/C lines.....

[eTiMaGo]

I was thinking of watching some porn tonight but now I don't need to :D great job so far, gonna follow this thread closely!!

[cali yaris]

I was thinking of watching some porn tonight but now I don't need to

Good. Send it back, please.

[Focus_Sh1ft]

Originally Posted by eTiMaGo

I was thinking of watching some porn tonight but now I don't need to :D great job so far, gonna follow this thread closely!!

Haha, if you want porn I should show you how cut up my hands currently are.

And now, here's day two of the install. Lot's of annoying things to slow me down (including work ). Just wanna point out that I had to change cameras, and this one isn't as good. I'll try to get the other back for Sunday. Anyhoo...

AC lines couldn't come out, so I moved them to the side a bit. Turns out there was an o-ring. Guess what? It blew.


However, there were two issues that were such a pain in the ass to get off...


Both of these mounts were part of the OEM header assembly. However, they were totally in the way of the Zage downpipe.

Here's the turbo/mani/downpipe with lines attached finally fitting in.


The money shots...


From the bottom


First intercool pipe added


As you can see from the above, downpipe fitment is PERFECT. Well, except for this one problem.


Turns out the OEM downpipe bolt on the right side begins to hit the downpipe. No problem, it was a quick fix with a hacksaw and power sander.


So here's the recap and where I'm at. Thus far, everything has fit perfectly. The only complaint I have is how impossible it is to get the bolts on the manifold tight. I can't get any type of wrench on them because the manifold blocks access from all directions. I can't even think of a tool that could be used, so I'm open to suggestions. The other potential issue I may have is the fitment problems of one of my coolant adapters on the turbo. This is not Zage's fault. For whatever reason, one of my compression nuts doesn't want to thread properly. I threaded it as much as possible and JB welded it. Nervous, but won't know until the car is running.

I also am unsure as to whether or not the feed line is going to make it to my sandwich adapter, but that's no biggie I suppose. Otherwise, my only other concern with the Zage kit beside the mani bolt issue is the intercooler piping. I sat for awhile today trying to figure out how the hell there's enough piping to run from the turbo all the way around to the TB. In particular, it seems like there could very well be a piece of piping that is missing. I'll be looking into this more.

Just remembered. I was a little concerned about the return line as well for two reasons. Now that everything is mounted up and I've seen the line run to where it would be IF I was using the Zage oil pan, I now understand it's problem. cdydjded was right - the return is a TERRIBLE design. The line would run horizontally to one side of of the oil pan to the back corner on the other side, whereby it would bolt in. That aside, even with my plan to tap the block above the pan I still am in a tough spot. The return line is too long and rigid to tap approximately where Garm tapped (pictures a few pages back). I'm gonna need another spot somewhere near there... I think I just need to spend some time looking at it.

Otherwise, everything is going pretty well so far. I thought I would be progressing along a little quicker but not only am I pretty inexperienced, I really would like to get this right and working.

EDIT: Just looked at their install pictures. I think I understand how they did the piping, but I believe they removed sections of plastic / metal (not sure what it is atm) next to the radiator (at the bottom) to work it around.

[coheed]

Very nice progress. Lol Ive been checking here all day waiting for the update. How much did you have to cut off of the bolt for it to clear the down pipe?

Looking at the Zage website Id say your not missing any ic piping. Thats a bummer.