GTX1000 install

[azshantris]

The time has finallllyyy come. I got lucky and landed a long work trip out of country for a few months and used the time and extra pay to order up a GTX1000 kit from BigBoost and all the other goodies I'll need. I'm currently in process of the swap and waiting on some fittings as I've found things that I needed or could do differently as I've gone along.

-BigBoost GTX1000 (custom order for my E series PWG 135i. That's a Garrett GTX3584RS as a T3 twin scroll with a 39mm Precision external wastegate and all the plumbing)
-M4 Dual Mass Flywheel
-GFB G Force 3 Boost Controller + MAC
-Precision Raceworks Walbro 535 setup
-Nexsys B58 coils kit
-Burgertuning 3.5bar Tmap kit
-Tune by Steven at Wedge
-Burgertuning N54 charge pipe with Tial BOV and MAC to control it
-Bunch of vacuum/boost lines and fittings
-Previous bolt on upgrades and whatever else I've forgotten

I'll update and add pics as I go. I'm so hyped for this, I've been waiting almost 4 years to get a bigger turbo for this bad boy and I'm definitely trying to do it right. The biggest upset is probably that I don't have E85 anywhere close enough to be worth it yet so I'll just be on 92oct. Wish me luck!

 

[wheela]

Nice to see a big turbo n55 build, excited to watch this progress!!

 

[Torgus]

Do you mean T4?

 

[azshantris]

Do you mean T4?

Nope, T3, from the listing and from the box. Not certain why, I'm a newbie with some of this still.

Edit: After some reading this may be a T3/T4 style setup. The exhaust side is T3 but the compressor side is larger.

 

[SLOWESTN54]

Aye nice! Stock motor?

 

[azshantris]

Aye nice! Stock motor?

As long as she'll last, yep.

 

[houtan]

Congrats. Looking forward to watching the progress.

 

[azshantris]

So this project was going well until I hit a few roadblocks. Currently trying to get in touch and work with Juan at Bigboost because I have some missing parts and some fitment issues. But I chugged along through the weekend and got a bit further. Waiting on some turbo coolant lines to come in from him but I got impatient and ordered a set from Amazon that I'm gonna try. The main issue now is the fitment of the inlet and outlet of the turbo. What I received doesn't look anything like the install pics and I can't seem for the life of me to get any of it to fit correctly. I can either fit the inlet OR the outlet, but not both. There isn't enough room no matter how far i try to force the elbows around to fit the short filter that came in my kit. Even if i relocated the coolant tank. I'm pretty savvy considering how far I've gotten with the rest of it.
There was an incorrectly sized elbow, the engine mount bracket interfered with the oil tube and after bending it the supplied hose was too short. The stock hose that should have reached the new cooling pipe branch was too short as well. Definitely some frustrations, but it is a custom kit and I expected a few pieces to need to be massaged. Like the dump tube rubbing the transmission housing, easy fix with just a little bending.

I think I can still get the exhaust side done and installed but I'm gonna need something different for the inlet/outlet situation. I already have a 3in - 2.25in coupling and a short section of tube to adapt the size to my bigger intercooler though I'm not sure what the 2.25 hose would have ever fit anyways considering the sizes of the intercooler I've seen.
I think a 2.5in elbow and the custom piece I see in some of his other pictures would work much better than the large U that I received.

Wish me luck fellas.

 

[azshantris]

Also, don't judge my zipe ties.. unless they blow off and I have to change them out lol

 

[houtan]

nice work.

The turbo to intercooler connection is a challenging one for sure. There is a lot of stuff going on in that area. Looking forward to seeing how big boost expects you to fix that part.

I was confused when you mentioned running a mac for boost control and one for the BOV. The one for boost control makes sense. What are you using to control the MAC for the BOV and why is that needed? My turbo has an internal turbo smart wastegate and turbosmart DV so I only have one MAC for boost control connect to the GFB ebc.

 

[azshantris]

nice work.

The turbo to intercooler connection is a challenging one for sure. There is a lot of stuff going on in that area. Looking forward to seeing how big boost expects you to fix that part.

I was confused when you mentioned running a mac for boost control and one for the BOV. The one for boost control makes sense. What are you using to control the MAC for the BOV and why is that needed? My turbo has an internal gate and turbosmart DV so I only have one MAC for boost control connect to the GFB ebc.

I sure hope he comes up with something and soon. I started my order request back in June, paid in September, recieved it in November, and now I've had my car down over a week trying to install it.

According to Steven from Wedge you can run the stock doverter wiring to a MAC and it will operate the BOV by switching between vac and boost based on the way I have it hooked up. I'm curious to test the function of it once I get everything else up and running. The reason for having it is because being external wastegate I lose the stock diverter. Granted, there are options to plumb that in at least on F series. But it's just a 12v solenoid so it makes sense why you can make the switch. I was worried to not have a diverter or BOV for the life of my turbo.

Very surprised to hear you have an internal wastegate!

 

[azshantris]

Also of note, the custom fitting that goes to the block for the turbo oil feed broke immediately when I put a wrench on it so I had to weld it back together. I really hope this all comes out well. Im not trying to bash at all and i usually have good experiences and I was recommended to BigBoost over Speedtech but even just the parts in their pictures look like they might have been worth the extra 500$, plus they list as an actual T4.

 

[Dumaurier7]

According to Steven from Wedge you can run the stock doverter wiring to a MAC and it will operate the BOV by switching between vac and boost based on the way I have it hooked up. I'm curious to test the function of it once I get everything else up and running. The reason for having it is because being external wastegate I lose the stock diverter. Granted, there are options to plumb that in at least on F series. But it's just a 12v solenoid so it makes sense why you can make the switch. I was worried to not have a diverter or BOV for the life of my turbo.

Very surprised to hear you have an internal wastegate!

This is correct and it works, but it's not actual vacuum, the boost signal ALONG with spring pressure keeps it closed when in boost then the boost pressure in the charge pipe pushes it open when activated on throttle closure, because of this it is important to utilize a soft spring to get it to respond properly/quickly. I run an upgraded Turbosmat Kompact BOV on the cover of my BW turbo together with a Mac tiggered Tial BOV on the charge pipe, I wired them in parallel so the both open at the same time.

 

[azshantris]

This is correct and it works, but it's not actual vacuum, the boost signal ALONG with spring pressure keeps it closed when in boost then the boost pressure in the charge pipe pushes it open when activated on throttle closure, because of this it is important to utilize a soft spring to get it to respond properly/quickly. I run an upgraded Turbosmat Kompact BOV on the cover of my BW turbo together with a Mac tiggered Tial BOV on the charge pipe, I wired them in parallel so the both open at the same time.

View attachment 76082

I did actually run vacuum to my BOV from the aux port on the vacuum pump since I don't need it for the wastegate or exhaust

 

[azshantris]

Next update but no photos. Spent over an hour trying to get the downpipe in and even without the O2 sensors the Vband tries to interfere with the motor mount if not clocked just right and the pipe itself hits the rubber connector for the cooling tube from the block. Gonna need some more massaging for sure.

 

[azshantris]

Finally got the downpipe in after disconnecting the coolant pipe and clocking the block adapter forward to clear. Then to get the coolant pipe back on I had to disconnect it from the water pump. To finish that portion I'll probably have to try a different shaped elbow or shorten the one I have to get it to line up.
Also got the outlet side installed by using a 2.25 to 3 reducer, a 2.25 short nipple, and cutting both ends of the supplied hose to fit.

So what I have left is to connect the coolant pipe to the water pump somehow, get the charge pipe back on *without pinching the damn O-ring* and leak test it, figure out how to get the inlet filter to fit, and then put in the coolant tank and leak test that system. And then the general underside reassembly after I do a transmission service.

Still waiting on communication for the turbo coolant lines that were supposedly sent out on the 22nd, and for more pictures showing how the inlet is supposed to fit.

Oh and waiting on Nexsys to send the updated coil boots and springs the they get them in, but that's a separate thing and I can get the car running before those are in anyways.

Slow and steady wins the race or something like that right?

I just wanna go fast ‍

 

[azshantris]

Got the current outlet setup to hold pressure so at least that's good. Not sure how to get the coolant elbow or inlet on yet. I ordered some other couplings to route it different so I can connect to the stock inlet like you're supposed to be able to though so that's exciting. Also ordered a master coolant pressure test kit so I can test the system while I still have the car up. Got at least until next weekend before I get to drive her again, but things are slowly starting to look up again.

 

[azshantris]

Got the supplied coolant pipe in after having to bend the sections a little more to shorten the dimension enough to fit between the block and the water pump connections.

Got the coolant test kit off Amazon and checked the system dry to see how it was and all looks good so I'm glad for that. Still taking the expansion tank in and out for fitup, that's why I didn't fill it yet.

Could not for the life of me get the supplied inlet/outlet setup to fit both at the same time, have not received further help from Bigboost and tomorrow marks 3 weeks since the missing coolant lines were supposed to ship. But I just want my car back sooooo amazon orders here I come. Did some studying and measuring and ordered a 2.5-2.25 in 135degree elbow, another 2.25 short alum pipe, and a 12in section of 2.25 silicone, plus clamps. No more connections than the supplied setup, just a more direct and compact path with which my prospect of fitting the expansion tank and inlet look significantly better. Had to do some trimming but it's coming along well and though it's a bit of a pain to fit in, it is at least fitting in.

Plus blue is cool

Haven't decided yet if I'm going to run the stock inlet upper to my BMS intake or do something else. I'd like the Injen, however I suspect it would interfere with the blow of valve location. Might need to modify the stock pipe and add a silicone coupling to hold it together with some allowable wiggle room, as getting the supplied 3in inlet pipe into the plastic pipe with the gasket in was impossible, even on the bench with lots of lube.

 

[houtan]

Nice progress. Have you consider the Turner relocation coolant tank? It’s pricey but it will open up the space for the turbo to intercooler connection.

 

[azshantris]

Nice progress. Have you consider the Turner relocation coolant tank? It’s pricey but it will open up the space for the turbo to intercooler connection.

Yeah I've looked at that or piecing together something similar. I'd prefer not to if I can avoid it because I was never informed that I should need something like that with my kit purchase and expected it to fit. I haven't ruled it out completely yet, but meh.