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DIY Turbo Discussion greddy on a 1.8? homebrew kit?

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Old 09-15-2007, 12:18 PM   #1
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Default Mommy please help me, it hurts

i've been working for the past week full time on installing my turbo

maybe i'm slow but it's been all sorts of stupid little things holding me up like tonight i spent 2 hours trying to shove the sleeve onto the BOV.

i was actually supposed to go to santa cruz for vacation tonight but i cancelled because my car is still not mobile

is there anyone in the dc area that would be willing to help me finish this kit up?

here's what's left on my 2003 begi s5 install:

intercooler piping
BOV piping
turbo piping
putting the turbo and manifold in the car
wiring up the hydra air temperature sensor
wiring up the hydra electronic boost control solonoid
install boost gauge
install and calibrate EGT gauge


i have beer, cash, fine hard liquor, sex, drugs if you can help...

i realllllly would like to finish this install and fire it up this weekend.

please let me know if you want to turn some wrenchess, thanks. i'm in columbia, md
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Old 09-15-2007, 01:06 PM   #2
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I'm sure hustler will help- he decided on, purchased and installed his turbo set up in one weekend.
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Old 09-15-2007, 03:38 PM   #3
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Quote:
Originally Posted by faeflora View Post
i have beer, cash, fine hard liquor, sex, drugs if you can help...
Are you a pimp? cause I ain't into man sex.
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Old 09-16-2007, 02:39 PM   #4
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Haha...beer and sex...ok! I would do it just for a ride in an S5 car.

Would love to but I wont be home till this weekend...ish?

Somebody help this guy out.
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Old 09-16-2007, 02:47 PM   #5
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i'd help but the weekend is ending.
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Old 09-17-2007, 11:12 PM   #6
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welll i finished up everything on the list with the help of zip ties and some pvc pipe (don't ask about the pipe please).

just turned on the car to calibrate the hydra o2 and my worst fear happened. fuel started to pour out of my engine.

i have a FFS fuel rail and it's looking like i didn't seat one of the injectors properly to the rail???? sigh hopefully there's no special tricks i'm missing to secure the injectors to the rail. i'd think that they wouldn't just sit on the rail.....
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Old 09-17-2007, 11:25 PM   #7
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lube them lightly with astroglide before you put them in the rail
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Old 09-18-2007, 12:32 AM   #8
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OK well i pulled the upper intake manifold and it's leaking from all over the dual FFS feed fuel rail.

the barb where it connects to the fuel line
the bungs on the rail.

AND

at two injectors

WTF


ok so for the barbs i'll use permatex on the threads...

now for the inejctors

WHY does it leak at the injectors? is it because i lost the spacers for the rail and the injectors have to be placed at the block just..so?
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Old 09-18-2007, 12:37 AM   #9
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you DO need to use the spacers for the rail, i actually lost one of mine a while back and used 2 washers and it was fine but i have the proper spacers in now
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Old 09-18-2007, 04:07 AM   #10
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yes you will need some sort of spacer inorder for the o-rings to be tight enough, yet not too tight to pinch one of the o-rings and ruin it, which might be the situation you're in.

when I replaced my injectors and did the diy dual feed fuel rail, I had a leak at one of the injectors, turns out the harness plug was rotated just enough to catch on one of the "lips" left over from when they cast the manifold. hardly detectable, but once I rotated the injector plug out of the way it sealed great.
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Old 09-20-2007, 08:46 PM   #11
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hallelujah... i got the thing on the road without any fluid hemorrhages. JOY

but apparently my car has a vacuum leak because when i shut off the ISC valve (zero it out) in the hydra and close the throttle plate the car keeps on chugging away... at 3000 RPM.

i set up my knock sensor threshholds but haven't done my base timing yet... i really don't know how to :(

umm i started to autotune but i guess any data harvested is useless if my car has a vacuum leak. it's big enough that if i get the car rolling in first gear it'll accellerate even if my foot is not on the throttle. i'm guessing that means i'm leaking around the intake manifold perhaps???

oh yah... my car is also barely making any more power. with my setup even with a horrible initial tune i should be making over 170whp at least i assume. maybe that's because of the leak too??

well tomorrow i'm gonna check all the piping and mebbe take the intake manifold off and reattach
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Old 09-20-2007, 09:01 PM   #12
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if you took the intake manifold off and it didn't seal up well when you reinstalled it that would definitely cause your revs to race and leak out your boost
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Old 09-21-2007, 04:49 AM   #13
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haven't done the tear down yet but it's weird because the boost gauge shows like 6-10lbs of boost but there's not really any additional power.... andd the boost line is sourced off the *** of the upper intake manifold.
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