TURBO KIT INSTRUCTIONS

Transcription

1 Revision 12/20/10 TURBO KIT INSTRUCTIONS This turbo kit consists of the necessary parts to upgrade or add a turbo to your 22R/RE/RET. This kit may require some fabrication to address your particular application such as intercooler location, exhaust system layout etc Note: This kit does not address the fuel injection management or ignition control issues. LC Engineering offers engine components and other accessories to modify your engine assembly as needed to perform with this turbo kit. Please call our technicians if you have any questions on your specific application The following are not step by step instructions. They are a general outline of how to install your new turbo kit. Please read through this completely before installing your new turbo kit. Lower Radiator Tube The Lower Radiator Tube may need to be adjusted out to provide adequate clearance for the Turbo Header. Heater Tube Relocation If your vehicle has a heater using the stock water tube running along the exhaust side of the block you will need to adjust the end of tube toward the firewall to clear the exhaust down tube. Turbo Header Assembly Install turbo header onto head using the exhaust gasket and new stud kit. Install studs into head, snug tight only. Tighten nuts to 33ft-lbs; re-torque nuts after approx. 100 miles. Install turbo to header, using hardware and gasket provided. Install exhaust downpipe onto turbo using hardware provided. DO NOT TIGHTEN YET! Leaving the downpipe slightly loose will allow for some movement that may be required for proper fitment of the wastegate downpipe. Tighten once all components are in place. Oxygen Sensor Due to various different applications we supply this kit with weld on oxygen sensor fittings for both; 2 bolt style (stock) and thread in style (Bosch or wideband) oxygen sensors. You will need to install one or both of these flanges to run an oxygen sensor with this kit. Wastegate Install wastegate and bypass tube with gaskets to exhaust tube-using hardware provided in kit. It may be necessary to leave downpipe bolts and wastegate bolts loose to allow slight movement of all components to obtain proper fitment. Once the wastegate and crossover are installed you can torque down the turbo to header, turbo to downpipe and all wastegate and crossover hardware. No sealant needed on any of these gaskets. You may use a small amount of sensor safe silicone on the wastegate crossover where it clamps into the downpipe.

2 PCV Valve LC Engineering recommends removing the PCV valve on ay boosted application. If you retain the PCV valve it will send pressurized hot oil into the cylinder walls and can damage the engine! We supply a PCV breather with the kit to eliminate the PCV valve on your engine. Oil Drain The kit comes with a braided stainless steel oil drain line. Install the aluminum plate to the oil drain on the turbo. Install 45 fitting into the plate (use a small amount of thread sealer, such as teflon paste). This fitting can be clocked to give you the desired angle for drain hose clearance. On stock 22RET blocks you can use the stock drain location with our oil drain flange (part # not included in this kit). For all other applications you will need to install an oil drain fitting onto the oil pan. The oil drain will be located on the oil pan just below the pan rail (you will want to place the drain fitting as close to the pan rail as possible while still leaving enough room for the drain hose fitting to clear the pan). Use the supplied oil drain line to determine the oil drain fitting location (front to back location). Mark the location on the oil pan. Remove pan, drill hole and weld fitting to pan. Clean, debur, paint, and reinstall pan. Install the other 45 fitting onto the oil drain fitting on the pan (or the new flange for stock turbo blocks) (use a small amount of thread sealer, such as teflon paste). This fitting can be clocked to give you the desired angle for drain hose clearance. Install the oil drain hose to prevent contact with exhaust header, steering shaft etc Warning: Blow out hose using compressed air before installation to remove any debris. Oil Supply Hose (22R/RE/RET) On stock turbo blocks you will need to plug the factory oil feed line with a 12mm x 1.25 bolt (not supplied in kit). Install the supplied 90 fitting on the turbo using a small amount of thread sealer. On right side (passenger side) of block there are 2 oil galley plugs that you can use (see pic). Install the supplied 28bspt to -4an fitting in whichever oil galley boss you are going to use (use a small amount of thread sealer). Use the supplied adell clamps and bolts (or use existing hardware depending on where you use the adell clamps) to route the oil feed line. Install the oil feed line with the 90 fitting end coming from the oil galley fitting and the straight end of the hose going to the turbo. The oil feed line is long enough to route up the passenger side to the top of the head, around the backside of the valve cover, and back up the drivers side of the cover and over to the turbo. Warning: Blow out hose using compressed air before installation to remove any debris.

3 Compressor Exit Hot Pipe The compressor housing will need to be clocked into position to fit your application. When you install the turbo onto the header you will need to loosen the compressor retaining bolts up slightly to allow the compressor housing to rotate. Make sure that you only loosen them a slight amount so the housing stays in line and does not damage the compressor wheel or shaft. The compressor outlet should be point towards the passenger side fenderwell to fit our hot pipe. Using the supplied T-bolt clamps install the supplied 90º silicone hose to the compressor exit of the turbo (this hose may need to be trimmed on one or both sides to fit properly). We supply a 2-piece hot pipe to go between the turbo and the throttle body. Install the longer section of the hot pipe into the 90º silicone hose off of the turbo. Install the shorter section of the hot pipe onto the throttle body using the silicone reducer and supplied T-bolt clamps. Use the silicone coupler to connect the two pieces of hot pipe together. You may need to adjust the rotation of the turbo compressor housing, compressor inlet hose and the hot pipe rotation to get everything to fit properly. This is a lot of tubing crammed in a small space so verify that you have clearance between all parts and the hood. Make sure that you retorque the compressor housing bolts after you have it clocked into position. Compressor inlet Install the 45º silicone connector using the supplied T-bolt clamp onto the compressor inlet (center opening). The silicone hose may need to be trimmed down to fit properly (usually you will need to take about 1 off the turbo side of the silicone hose). Install the supplied intake tube and bracket to the 45º hose using the supplied T-bolt clamp. Use the supplied bolt and wave washer to attach the bracket to your fenderwell. You may use the existing threaded hole or drill a new hole as needed (this bracket is designed to fit most applications; some modification may be needed to work for your exact application). Install the K&N air filter onto the end of the new air tube and bracket assembly. Warning: This intake tube and filter application is not designed to be used with the stock mass airflow sensor.

4 Variable Boost Controller Install boost controller in a convenient location in cab. You won t need to adjust this often after your initial settings. Route hoses in safe location and tie existing wire loom to hold secure. Install hoses to boost controller and waste gate (see pic). 22RE installed Turbo Hardware Kit Header Mounting Studs Oil Drain Flange 8 M x 50mm Studs 2 M x 25mm Hex Bolt 8 M Flange Nut 2 M Flat Washer Header To Turbo Wastegate & Crossover 4 M x 40mm Stud 4 5/16-18 x 1 Hex Bolt 4 M Serrated Flange Nut 4 5/16 Flat Washer 1 ¼ -20 x 1 ¼ Allen Bolt Turbo To Downpipe 1 ¼ -20 Locknut 5 M x 30mm Stud Oil Feed Line Adell Clamps 5 Copper Cleve Lock Nut 5 M x 12mm Hex Bolt Downpipe Flange 5 M8 Wave Washer 2 3/8-16 x 1 ½ Hex Bolt Intake Tube 2 3/8-16 Flat Washer 1 M x 12mm Hex Bolt 2 3/8-16 Locknut 1 M8 Wave Washer

5 TURBO ENGINE SET-UP ISSUES Turbo charging any engine increases the strain on all of the engine components. At each level of additional boost, new issues for engine configuration develop and need to be addressed. Keep in mind; it is the combination of matched components that will deliver a reliable high horsepower engine. What works for a low boost application may not take the strain of high levels of boost. Following are some guidelines to consider when setting up an engine for turbo or blower use. Camshaft LC Engineering offers specially designed camshafts to achieve full benefit of your turbo engine. We offer custom ground camshafts for all levels of boost and rpm ranges. For most low boost street applications, our Street Turbo Cam (part # ) is an excellent choice. Please call and talk with our technical staff about your specific requirements and for a recommendation. Valves, Valve Springs and Cylinder Head For the most performance, valve size, valve springs and cylinder head porting need to match the desired level of boost and camshaft profile used. Our Street Performer cylinder head (part # ) will be adequate for most low boost 4WD and 2WD street applications. For higher performance use, even at low boost levels, we recommend using our Stage 2 or higher cylinder head with Pro Dual Valve Springs, upgraded Retainers etc... Our Pro Cam Kit (Part # ) should be used if you are rebuilding your cylinder head for most applications. Compression Ratio To achieve a reliable turbo charged engine package, you will need to lower your mechanical compression ratio to match the boost level you plan on running. This can be done on stock EFI engine by changing the pistons during a rebuild. We offer both a Street Performer cast pistons and our racing forged piston kit that will achieve this compression ratio. Cylinder head and block modifications can change the compression ratio. Always cc your components during assembly to verify the mechanical compression ratio. Please call our technicians if you have any questions on your specific needs. Bottom End The stock bottom engine has adequate strength for low boost and low rpm applications. For higher levels of boost and performance our Pro bottom end components (Pro Crank, Pro Rods and Forged Pistons) should be used. For higher horsepower levels or turbo/nitrous applications please call our technicians for specific recommendations.

6 Fuel & Ignition Management LC Engineering offers the LC Pro Fuel Injection Kits or Mass Airflow Conversion Kits that will control the fuel curve and Ignition timing. Generally you will need larger injector s additional sensors for higher boost applications. Please call our technicians for a specific recommendation. Intercoolers Intercoolers allow the use of high boost levels and increased performance. There are many different intercoolers designs and locations to position them. Please call our tech line for specific information on the intercoolers. LC ENGINEERING TURBO ENGINE RECOMMENDATIONS These recommendations are a guideline for the type of modifications needed to build a strong and reliable engine for the desired level of boost and performance. Please talk with a technician about your specific requirements before to ordering. Low Boost Accessories Recommendations 0-10 PSI Boost Cylinder Head Studs Pro Oil Pump Street Turbo Cam Street Performer Valve Springs Low Compression Street Pistons Pro Rod Bolts Pro Fuel Injection Pro Head Gasket Medium Boost 10+ PSI Boost Cylinder Head Studs Pro Oil Pump Custom Turbo Camshaft Pro Cam Kit w/ Dual Valve Springs Pro Head Gasket Forged Piston Kit LC Pro Rods Timing Chain Conversion Kit Pro Fuel Injection Heavy Duty Radiator