Irace86.2.0's KPower Turbo K24 Swap

[Irace86.2.0]

Originally Posted by brzlegend

Glad I dont use precision waistegates.

Like I said it works and your turbo is way to small to worry about wastegate placement. Small turbos work off pressure, large turbos go towards the velocity side of things.

If you really want to rack your brain study compound turbos where they drop engine backpressure by adding a big turbo after the small one exhaust wise, at the same boost.

I won’t interupt anymore, as the saying goes.

Well, that was just one stock image of many that all say the same thing over many manufacturers, but it is good to know that I can invert it without it being a big problem. Thanks. I may have to do that.

[Irace86.2.0]

I did a little work on the car when I finished studying for my final tomorrow. I got the shifter and driveshaft in after having to go to the dealership to get some of those black washer/spacers; mine were practically glued to the stock rod and broken.

I wasn’t down for cutting the bracket like the directions said. I was going to just weld it real fast, but I would have had to swap guns and tanks and just said hell with it and put a kink in it to shorten it up. Seemed to work, and now the center console is a little more stable than it would have been without the bracket.

[Irace86.2.0]

I made a bracket for the FF sensor, and I mounted it to the manifold. I used a 90 degree 3/8 quick connect to 5/16 barb, and I have a straight connector coming in the mail to finish it off. I cut the stock line just behind the 5/16 quick connect, and I added the 3/8 piece, and it reached pretty easy.

A few shots of the rear lines. One is plugged and zip tied. The EVAP line is just vented and dumped. The feed line has a piece of one of the lines I pulled attached, so I can drain my tank of old E85 when I get the car all hooked up. I probably should have kept a longer line, so I could just do this easier from the engine bay off the other lines. Actually, I might do that with the extra fittings. Hmmm. Anyways, that is the current setup.

I don’t think I showed the picture of the oil lines. 120 degree fittings on one side and 45s on the other side with a low profile 90 degree fitting to clear the stock airbox at the top.

[Irace86.2.0]

I haven’t updated this in a while. Holidays had me busy, and I was waiting on some parts.

I mounted the Haltech ECU in the glove box using some well-nuts to keep it in place. I cut the glovebox down to clear. I don’t use my glovebox for storage, so this wasn’t a big deal. I wanted it in a place with easy access, yet somewhat not obvious. It can’t be seen from the seats when opened.

It was a tight fit routing the wiring harness and getting the old ECU to fit back in the bracket because of the harness going out the rear hitting the firewall.

[Irace86.2.0]

I worked on the intercooler piping. I am planning to just tape the pipes together, and then I’ll have them welded. I realized I needed a 90 3” elbow to clear the hood. All I had was two 45s. I’ll finish the intercooler piping later this week.

[Irace86.2.0]

I got the stainless steel elbows. I cut off the old wastegate pipe that was angled up and blocking the gap for the downpipe. I opened the hole back up and cut it all to clear. I decided to just MIG weld it myself. Then I wrapped it in heat wrap. The turbo then got permanently mounted. The last picture is the former position of the wastegate. The subframe cupped area lateral to the engine mounts, the one for the header/midpipe provides an excellent space for the inverted wastegate, so there is lots of clearance. I’ll be working on the downpipe and wastegate dump tube next.

[Ebush]

Originally Posted by Irace86.2.0

I haven’t updated this in a while. Holidays had me busy, and I was waiting on some parts.

I mounted the Haltech ECU in the glove box using some well-nuts to keep it in place. I cut the glovebox down to clear. I don’t use my glovebox for storage, so this wasn’t a big deal. I wanted it in a place with easy access, yet somewhat not obvious. It can’t be seen from the seats when opened.

It was a tight fit routing the wiring harness and getting the old ECU to fit back in the bracket because of the harness going out the rear hitting the firewall.

Wow you really cut away the whole glove box. I was able to leave my glove box nearly 100 percent in tact. Just a small section cut on the right side to keep it from hitting the jumper harness loom, and then about a half inch cut that was a few inches wide on the back side. Glove box still has full capacity and I can open/close the glove box even with the yellow cable plugged in.

[Irace86.2.0]

Originally Posted by Ebush

Wow you really cut away the whole glove box. I was able to leave my glove box nearly 100 percent in tact. Just a small section cut on the right side to keep it from hitting the jumper harness loom, and then about a half inch cut that was a few inches wide on the back side. Glove box still has full capacity and I can open/close the glove box even with the yellow cable plugged in.

I cut the glove box instead of cutting into the big plastic piece that makes up the lower dash like you did to raise the harness. That required clearing a lot of the side. Then I just cut straight across because I really didn’t care about the glove box. I can get an used one for $20-40 if I want on eBay, but I don’t ever use or open it, so I probably won’t. Cutting the box so much definitely isn’t required.

[Mike_ZN6]

Looks like a tight fit for that turbo! Thanks for all the updates.

[Irace86.2.0]

Originally Posted by Mike_ZN6

Looks like a tight fit for that turbo! Thanks for all the updates.

If someone was designing a turbo manifold for this chassis then they would want to lean the manifold towards the front to clear a spot for the downpipe and raise the turbo up higher. My G25-660 clone is a small turbo, but there is room for a large turbo if such considerations were made. Case in point can be seen here. Note the wastegate pointing forward, the turbo sitting to the top of the engine, but it also looks like he went to a remote oil filter to clear the intercooler pipe.

The downpipe should clear with a few centimeters all around after my provisions.

[Ebush]

Originally Posted by Irace86.2.0

I cut the glove box instead of cutting into the big plastic piece that makes up the lower dash like you did to raise the harness. That required clearing a lot of the side. Then I just cut straight across because I really didn’t care about the glove box. I can get an used one for $20-40 if I want on eBay, but I don’t ever use or open it, so I probably won’t. Cutting the box so much definitely isn’t required.

Yeah I see that now, I guess it’s a bit harder to install the ECU right there without removing that giant lower dash piece. I removed it all and modified it on a bench, then installed into the car. If the yellow cable isn’t plugged in, you can’t even tell the ECU is in there.

[Irace86.2.0]

I started with assembling the turbo AN lines and decided to tackle more of the IC piping instead of the downpipe. I’ll start that tomorrow.

[Irace86.2.0]

I got my 90 degree aluminum elbow today, so I was able to finish the intercooler pipes. The hood closes with room to spare. I just need to drill two holes for the BOV bung and IAT bung. The pipes can be removed, just in case anyone is thinking it wouldn’t.

I also finished all the major cuts and prep on the downpipe to frontpipe. I just need to do the dump tube. I have room for a flex tube for the downpipe, but not for the wastegate like I wanted, but it’ll be fine. Here are a few pics. Plenty of clearance on the downpipe.

[jflogerzi]

Originally Posted by Irace86.2.0

If someone was designing a turbo manifold for this chassis then they would want to lean the manifold towards the front to clear a spot for the downpipe and raise the turbo up higher. My G25-660 clone is a small turbo, but there is room for a large turbo if such considerations were made. Case in point can be seen here. Note the wastegate pointing forward, the turbo sitting to the top of the engine, but it also looks like he went to a remote oil filter to clear the intercooler pipe.

The downpipe should clear with a few centimeters all around after my provisions.

so pretty in that engine bay