It is profoundly unnecessary to know anything about the science and engineering of turbocharging to competently install a well-designed aftermarket turbocharger system. The installer need only be a competent hobbyist mechanic. The experience level is about equivalent to that of changing a clutch or removing and replacing an intake manifold.A German proverb clearly states the problem of accomplishing such a job :"The devil is in the details." To illustrate the accuracy of this proverrb, it is easy to imagine that most people could install an exhaust manifold correctly. Yet a simple air hose not properly attached to a fuel pressure regulator can keep an otherwise faultless system from functioning correctly. Therefore, thoughts about one's competence to install such things should center around how conscientiously one can do the details.
Follow instructions faithfully. When system has a street legal exemption order, it is absolutely necessary to follow instructions to the letter to maintain the legal status. Furthermore, the installer should presume the designer knew what he was doing.
There is some logic to the process. Read the instructions and make notes of questions, if any, to pose to the kit maker. It is both easy and natural for instruction writers to gloss over many points of installation, since they know all the pieces and processes intimately. Service is supposed to begin after the sale. You purchased a kit in good faith and were told that with modest ability, you could properly install it. You will likely need many points of the instructions addressed before and during the installation. It is entirely fair to require the kit maker to give you guidance on the procedure where necessary. Clearly, this form of feedback also improves the writer's ability to create proper instructions.
Familiarize yourself with the parts of the system. Learn the name the writer has given each part. Inventory the parts with respect to the packing list, to be certain all items were included. Call the manufacturer for shortages at the earliest opportunity.
No kit maker should be shipping parts less than spotlessly clean. However, it is a serious error to assume they are clean and ready to install. Any installer worth at least his weight in salt will insure that every part is perfectly clean.
The vehicle subject to the installation need not be in perfect condition. A proper installation on a 90% vehicle will, however, yield only 90% results. While clearly superior to stock, 90% is not the objective of this book or what this writer perceives as the objective of the fellow hard-core enthusiast. If something is mechanically amiss, fix it before the installation.
Prior to starting the installation, fill the fuel tank with gasoline of the octane suggested in the instructions. Do not dilute with lesser octane fuel already in the tank. If necessary, drain the tank. Never use octane boost as a testing aid -- it will mask many critical characteristics, such as air/fuel ratios and ignition timing controls. If unspecified, consider left and right from the position of the driver.
After the installation has begun, the best procedure is to complete the entire job prior to driving the vehicle. Certainly the job can be broken up into segments, like installing the boost gauge, fuel pump, heat shield, etc. The catch is, one cannot install only the turbo and associated pipes and then set out to see how fast it will go. That will surely prove a disaster.
Always read the statement of warranty prior to starting the installation. If questions of policy exist, this is the best time to discuss them.
The speed with which you accomplish the installation is not of any consequence. A few extra hours mean nothing.
Tools and Equipment
A reasonable selection of hobbyist mechanic's tools is all that's required for a successful installation :
- Metric open/box combination wrenches
- Metric socket set
- SAE open/box wrenches
- Assorted slot and Phillips screwdrivers
- Electric drill and assorted drill bits
- Ignition timing light
- Sealing compound
- Never-Seize compound
- Locktight #271
- Spray can of cleaning solvent
- Oil filter and oil change
- Teflon tape
- Safety wire
- Clean rags
- Floor jack
- Jack Stands
- Factory shop manuals
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