Turbo Swap - what else to replace?

[pjzabo]

Well I'm finally getting around to swapping out my turbo and installing a Vitesse Stage 3 kit I ordered a while back. Since the intake and turbo are out I am also replacing all the coolant hoses and vacuum lines. What else should I be looking to replace? The car has 88K miles on it and runs perfect with good compression. It definitely has a slight oil leak at the rear of the engine (see pic)



and the brakes, which have always been fine, looks like the master is weeping a little



So what gaskets and seals should I be replacing since all this stuff is off? I don't plan on doing the bearings and I rather leave the original head gasket - I'm in the school of thought on head gaskets to leave it alone if there is no problem.

Thanks for any advice -

Pete

[kdjones2000]

Well, it looks like your AOS seals need replacing, so I would get a set of those (~$5).

I did all of this on my car recently and detailed it out in this thread. There is a list of parts I used at the bottom.

Okay, here we go: The great fix it/upgrade thread

Good luck, Keith

[pjzabo]

Thanks Keith! You da man, great thread. Ordering the AOS seals today and will take it out and clean everything.

[Techno Duck]

There is alot you can do. Check my 2 threads here for an idea of what i did. One was when i had the head off, but alot of the work i did did not require remova of the head.. just intake manifold removal which you already have out of the way. The other is from my turbo swap thread.

http://forums.rennlist.com/rennforums/944-turbo-and-turbo-s-forum/417463-phase-one-of-my-project.html?highlight=phase

http://forums.rennlist.com/rennforums/944-turbo-and-turbo-s-forum/471766-phase-two-of-my-project-turbo-swap-pictorial.html

Here is what i would recommend to simplify and clean things up under the intake, aswell as those normal 'while your in there' things.


LR black knob boost controller
Cycling valve delete
New heater control valve
Replace AOS seals
Replace rubber lines for the ISV and brake booster
Replace battery all battery cables and headlight harness
Install Transpo voltage regulator
Replace all vacuum lines
Delete hard pipes under intake... you can simplify this with one silicone hose running under the intake when you delete the cycling valve for the MAF / Turbo install.

Other optional things are modifying the crossover to be 2pc (technically 3pc) with v-band flange to make turbo removal easier aswell as cut time off dropping the pan if you have to. Heat wrap the downpipe or have it thermal coated.

Stock mess


After deleting cycling valve and all the hardpipes


A great time to reseal the upper balance shaft also, mainly that rear most o-ring but you will need to get the belts off also.

[pjzabo]

Thanks Jon.

Question - where did you get the lines and fittings to replace the hardpipes and take out the cycling valve? I will be installing teh Vitesse MAF and a Tial 38mm wastegate with a LR black knob manual controller so I am all for cleaning things up underhood.

[Techno Duck]

Originally Posted by pjzabo

Thanks Jon.

Question - where did you get the lines and fittings to replace the hardpipes and take out the cycling valve? I will be installing teh Vitesse MAF and a Tial 38mm wastegate with a LR black knob manual controller so I am all for cleaning things up underhood.

I bought everything from BoostController.Com , They have good prices and are right in NY so shipping is quick.

You will want about 20ft of 5/32'' vacuum line and about 3ft of 19mm silicone tube for the crank breather. Also 1 90* 19mm elbow for the crank breather outlet. From there you need to decide how you want to attach everything to your MAF pipe and order whatever else you need. For the Tial wastegate fittings, you need 1/4'' silicone vacuum line.