If you're 16 and your mother just gave you her 95 GLT last week and you have no prior experiance on working on a car, this build is not for you!!!!!!!
Now with that out the way, my goal for this build was not only to turbocharge a non-turbo 850, but to do it effectively within a college student's budget (one step higher than homeless). Most of the major parts were picked off junkyard vehicles to keep the cost down. That being said, I went through 4 850's to find a turbo in great shape and the rest of the parts list is as follows:
TD04 15G
T-5 Exhaust manifold
850 T-5 intercooler and piping
Oil pressure sensor
2.5 inch to 3 inch silicone coupler
2.5 inch diameter pipe, approx 4 inches long
Drilled and tapped oil pan
Various brass fittings
3 feet of transmission cooler hose (rubber)
3 feet of 5/8ths oil cooler line.
4 feet of vaccum line
2.5 feet of fuel line hose (for PCV)
Slightly up rated injectors ( Im running 24lb/hr ones from a northstar STS)
T-5 air box
2.5 in down pipe back exhaust
Sunpro Boost Gauge
PLX M300 wideband afr gauge (sensor was bad when I bought it)
2 cases of Powerade (24 each case)
Total cost of parts: Around $500, give or take some Zaxby's chicken finger plates.
First thing I did was remove the front bumper assymbly and head lights along with that black plastic piece (holds the headlights, horn, and hood latch). This allowed me to gain access to the radiator and ac condensor core support. The intercooler fits right between the condensor and raidiator and can use the stock bolts. The turbo manifold bots right up to the NA head. Next I started to remove the oil pan for the turbo oil drain, which is the hardest part of this build. I used this http://volvospeed.co...l +pan +removal, took me 4+ hours to remove. Once removed, I drilled, tapped, and screwed a brass fitting into the pan. I screwed on a brass nut to the back of said brass fitting for extra strength and security. I added sealant around both sides of the brass fitting and JB weld on the outside (of the pan) surface. While I let that dry, I installed the turbo oil feed. For the source, I used the oil pressure sensor port. Unlike the RN motors, the port is not M12x1.5. I can't remember the exact size but I took the sensor itself to NAPA to get it size and to find a fitting that would fit. Thats where the extra oil pressure sensor comes into play. Just get it sized before you start the build. From the fitting at the oil pressure sensor sight to the oil feed hard line (just a flipped oil feed line with the larger banjo end cut off), I used trans cooler hose. By the time I finished that, the oil pan was ready to be reinstalled. After that gruelling process, the oil pan was back on the block. Now I could finish the oil drain. I cut about 3 inches of the oil drain hard line and ran the 5/8(id) oil cooler line from the hard line to the oil pan. I spliced into coolant reservior tank line and the lower heater core line for the water feed and drain lines for the turbo. I then ran the piping for the intercooler and used the silicon adapter at the throttle body and used the 2.5 in pipe to connect the adapter to the post-intercooler piping. I also connected the IACV to the vaccum tree at this time. So with all the major components on the car, it was time to reassymble the front bumper and what not. Put the car back on the wheels and attempted to start it. Started first time! But a few issues arose. There was a coolant leak at the water drain line that I couldn't fix, so I removed the line and capped the splices. I now have to turbo time the car before I shut it down, a little inconveniance.
Three months later and its still goin strong, although I may have a boost leak at the vaccume tree.
I'll post pics and video of the car once I fuigure out how to....
Forgot to add that I replace the injectors for 24# ones from a northstar STS or Eldorado. I run premium and only premium.
