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This is a discussion on Drag kit install manual in the Forced Induction forum
I found this in a text file on an OLD backup cd i have... didn't read it, but figured i'd post it to the archives These instructions are provided for the benefit of the end user. Installation should only be performed by a certified technician. ...
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|07-18-2004, 12:37 AM||#1|
I found this in a text file on an OLD backup cd i have...
didn't read it, but figured i'd post it to the archives
These instructions are provided for the benefit of the end user. Installation should only be performed by a certified technician.
DRAG COMPETITION PRODUCTS assumes no liability for any personal injury and/or mechanical failures resulting from the installation and use of this product. THIS PRODUCT IS FOR OFF ROAD USE ONLY.
1) Remove factory air box assembly, strut tower bar and disconnect negative terminal side of battery.
2) Add second fuel pump.
Cut the rubber fuel line approximately 1 1/2 inches from the fuel filter. Assemble supplied fuel pump with the shorter brass fitting. Insert hose barb connector into the 1 1/2 inch rubber fuel line extending from the fuel filter. Connect supplied rubber fuel line to barb connector and the second fuel pump. Connect stock rubber fuel line extending from fuel rail to the banjo fitting of the second fuel pump. Secure all lines with hose clamps. Note: Use the supplied hose clamp to secure the fuel pump to the air conditioning line. Ground the fuel pump to the engine or chassis. Using a wire tap connector, connect the positive terminal of the fuel pump to pin 4 of the factory fuel pump main relay located underneath the dash board (the main relay is a gray box which clicks when the ignition is turned on). Note: you must use a minimum of 14-gauge wire to connect the fuel pump terminal and relay. Reconnect the negative terminal and turn key to ignition position two and check for any fuel leaks. Repeat the process 3-4 times. Note: when connected properly, the fuel pump will run for about a second and then shut off. If the fuel pump constantly runs after the ignition is turned on, then the fuel pump is tapped into the wrong pin -- disconnect wire and connect to pin 7.
3) Disconnect negative terminal of battery.
4) Install boost dependent fuel pressure regulator.
Remove factory return line from factory fuel pressure regulator (located on the fuel rail). Secure factory return line to boost dependent fuel pressure regulator on the fitting labeled "OUT". Connect the fuel line on the boost dependent regulator to the factory fuel pressure regulator. Secure the boost dependent regulator to the strut tower. Cut the factory vacuum line that goes to the stock fuel pressure regulator. Connect the boost dependent regulator to the vacuum line using a t-connector. Reconnect battery and start engine. Make sure there are no fuel leaks. Disconnect the negative terminal of the battery.
5) Remove the stock exhaust manifold and down pipe. File down the webbing of the engine block located beneath the left side of the exhaust manifold. The block needs to be filed away approximately 1/4" to 1/2" to make room for the turbo compressor housing.
6) Loosen center section of turbo and install the turbo onto the turbo exhaust manifold.
7) Install the 90 degree "AN" fitting to the center section (DO NOT use any Teflon tape and/or silicone on the fitting). Rotate the center section until the "AN" fitting hits the turbo mounting bolt on the exhaust manifold. Back the "AN" fitting off the bolt so that it does not conduct heat. Tighten the exhaust side of the center housing.
8) Attach the turbo exhaust manifold so that it can be used to align the oil drain return pipe to the center housing and oil pan. The return pipe should be attached to the oil pan next to the bolt located on the shallow end of the oil pan and on the opposite side of the drain bolt. Mark the oil pan so that the oil return pipe can be attached to it.
9) Remove the oil pan. Drill a hole in the oil pan to allow the oil to return and weld the return pipe onto the pan as marked. Reinstall the oil pan.
10) Line up compressor housing so that the nozzle faces down. Tighten one bolt on the compressor housing. Remove turbo and exhaust manifold. Tighten all bolts on the compressor housing.
11) Place rubber hose on the oil return pipe extending from the oil pan. Place two hose clamps around the rubber hose. Install the turbo and exhaust manifold by inserting the center housing's oil return fitting into the rubber hose on the oil return pipe and then sliding the exhaust manifold onto the head. Tighten all nuts/bolts.
12) Secure hose clamps on the oil return pipe and center housing oil return fitting.
13) Remove oil pressure sending unit located to the left of the oil filter and replace with brass t-fitting using Teflon tape. Connect oil-sending unit to brass fitting. Connect supplied brass "AN" fitting to t-fitting using Teflon tape. Attach steel braided line to "AN" fitting (do not use Teflon tape). Route braided line across the transmission side of the engine and connect to the center housing (do not use Teflon tape when connecting to the center housing).
14) Remove bumper cover and bumper beam. Align intercooler along bumper beam, with the 2" port facing the driver side, so that it is centered and the bracket of the intercooler is flush with the rear of the bumper beam. Warning: make sure the intercooler is as close as possible to the radiator.
If you do not get it close enough, then you will have to cut the bumper. Mark the bumper beam and drill. Install the intercooler using nuts and bolts. Reinstall bumper beam.
15) Place silicone hose over turbo compressor outlet. Connect pipe 1 to compressor outlet. Cut a hole in the driver side front splash guard so that pipe 2 can connect to pipe 1. Attach pipe 2 to pipe 1 with silicone hose (make sure pipe 2 is pressed flush with pipe 1). Connect pipe 3 to pipe 2 with silicone hose. Connect other end of pipe 3 to intercooler with silicone hose. Install 90-degree rubber boot on the short end of pipe 4. Connect longer end of pipe 4 to the intercooler with silicone hose (make sure the boot faces up after pipe 4 is installed). Place silicone hose onto throttle
body. Connect pipe 5 to throttle body first and then to rubber boot (make sure bypass valve is attached to pipe 5 before installing). Secure all hoses with hose clamps.
16) Install aluminum adapter pipe to turbo inlet with silicone hose. Attach pipe 6 to adapter pipe with silicone hose. Secure all hoses. Attach air filter to end of pipe 6.
17) Remove map sensor (located on top of the throttle body) and replace with plastic 90 degree fitting of map sensor bypass assembly. Connect stock map sensor to bypass assembly. Secure map sensor bypass assembly with wire ties.
18) Install down pipe.
19) Install wastegate and wastegate dump pipe. Install 90-degree brass fitting on the side of the wastegate where it is labeled "boost" and connect to intake manifold vacuum source.
1. Add engine oil.
2. Add coolant if necessary.
3. Connect the battery terminal.
4. Remove the coil wire so that the motor will crank but will not start.
5. Hold the oil feed line for the turbocharger in an empty oil can and have an assistant crank the engine seven to ten times in spurts of ten seconds each. After 1/4 qt. of oil has filled the oil can, the oil feed line may be attached to the turbocharger. This procedure purges the oil line of any debris inside the line that may damage the turbocharger.
6. Replace the coil wire.
7. Recheck all connections and start the engine. Allow the engine to idle.
8. Check the entire system for leakage of coolant, fuel, and vacuum. Correct as necessary prior to driving car.
9. Set ignition timing to factory specs. PLEASE NOTE THAT THIS SYSTEM IS NOT COMPATABLE WITH AFTERMARKET CHIPS THAT ADVANCE IGNITION TIMING. ADVANCED IGNITION TIMING MAY RESULT IN DETONATION, WHICH MAY LEAD TO ENGINE DAMAGE.
10. Gap spark plugs to .030. NGK part # BCPR7ES-11 spark plugs are highly recommended.
11. MAKE SURE THE VEHICLE HAS AT LEAST 92 OCTANE GASOLINE.
12. The vehicle is ready for testing.
Testing / Troubleshooting
1. Vehicle must have stock ignition timing and at least 92 octane gasoline.
2. Locate suitable site for testing.
3. Drive vehicle very slowly around the block a few times. Listen carefully for any unusual sounds and note drivability. Do not go past 1/4 throttle at this stage. If any thing unusual is noted, determine cause and correct before going further.
4. If nothing unusual is noted, bring the vehicle up to 3000 rpm in second gear and shift into third gear. Slowly apply throttle until redline is reached. Listen very carefully for pinging or detonation. IF PINGING IS HEARD, LET OFF THE THROTTLE IMMEDIATELY. PINGING OR DETONATION CAN CAUSE ENGINE DAMAGE. If no pinging is heard, repeat in fourth gear.
5. If pinging is noted, carefully inspect fuel pump and turbo fuel pressure regulator systems as well as ignition timing. Fuel pump should emit buzzing sound when operating.
6. If no cause is found it may be necessary to retard ignition timing by 5 degrees and/or utilize colder heat range spark plugs. NGK part # BCPR7ES-11 are recommended.
7. If engine misfires at high rpm, verify that plugs are gapped at .030.
8. If check engine light comes on immediately during or after boost, check the Map sensor bypass system.
9. If check engine light is on upon starting car check oxygen sensor connector or consult ECU self diagnostics and service manual.
10. If no boost is present, check all intake hose connections for leaks, then check for exhaust leaks on the manifold to head, manifold to turbo manifold to wastegate, and turbo to downpipe areas.
11. If boost pressure is too high, verify that the wastegate is receiving a signal to its bottom port from either the turbocharger or the intake manifold.
12. Normal boost pressure for this system is 8.5 - 10 psi, depending on temperature and altitude. NEVER EXCEED 10 PSI.
Protection of the motor
1. Boost should not be used until the motor is up to standard operating temperature.
2. When operating under boost, the driver must at all times be concerned with detonation. This means listening carefully for a metallic pinging sound emanating from the motor. Should this sound be heard, or any functional change in the operation of the motor be noted, cease using boost immediately and correct BEFORE retesting, or motor damage will result.
3. Any attempts to achieve a maximum speed are strongly discouraged.
4. Never use less than 92 octane gasoline.
5. Do not increase the boost pressure in excess of the maximum setting suggested by DRAG.
6. Change spark plugs ( NGK BCPR 7ES -11are recommended ), air filters, and fuel filters every 10,000 miles. If your kit utilizes a K&N air filter, wash it at the above intervals.
7. Check the resistance of your spark plug wires at the time of initial installation (no more than 25,000 ohms) and every 10,000 miles thereafter.
8. Ignition timing must be stock. Never advance ignition timing or use an aftermarket chip, which may advance timing.
Protection of the turbo
1. On cold start up, the motor should be allowed to idle at the lowest possible rpm for 15 seconds to ensure lubrication of the turbo. You should then allow your engine to achieve full operational temperature BEFORE running it in a boost condition.
2. The motor must never be turned off while it is under boost.
3. Develop the habit of allowing the motor to idle for at least 15 seconds prior to turning the ignition off when you have just arrived at your destination driving in a normal manner. The recommended time of 15 seconds should be lengthened if you have just run the car in a vigorous, boosted manner. In other words, let the engine idle long enough (based on a sliding scale) to stabilize the exhaust gas temperature, and coolant and oil flow, before shut down.
4. Use high-grade oil and/or one formulated for use with turbo motors (DRAG utilizes 20-50W Mobile One).
5. Change the oil and oil filter every 3,000 miles.
6. When restarting the engine after an oil change or storage longer than a week, disconnect the coil and turn over with the starter to reestablish oil pressure.