I'd call Tim. He says hes done alot of in car installs so he must have a few tricks.

otherwise, borrow an engine crane. Its very simple to pull the motor. rrxmedic has a great pictorial and binder just did it as well with pics.

 

According to Tim i was on the right path... the screws have to be taken out then put back in with the header in place... The good news is i can get 4-5 in with out issue, its the 6th screw on the 5th cylinder exhaust. Well hopefully i can get it tonight

 

in that case, i wouldnt use studs, just use bolts

 

Small update: This week was spend finding machine shops to fix the bolt holes on the exhaust manifolds. I have the passengers side in...However I neglected to take the drivers when I went so that will need to be done this week. The oil reservoir that goes under the transmission also has holes that are just slightly off. The kit bolted together to its self, Im finding how everything from this kit that has had to be bolted to the car needs slight modifications.

Needless to say I will have a conversation with turbo tim when all is said and done for all machining done so far, and anything in the future to come.

Its weird the Welds are fantastic on the kit, just the machining seems to be out when it comes to mating up to my car.

I will post pictures when i pick up a new camera cable as I broke that in frustration ahah

 

Things can line up perfectly when tacked. Once you do a full weld however, things do move around. The heat from welding causes expansion and it is very easy to get things out of alignment.

I tack the crap out of everything before welding solid. It greatly reduces the chances of things moving too much.

That is why one should always test fit thigs when the piece cools off.

 

a drill bit worked side to side is more than sufficient to fix those problems

 

So Today was the breaking point, Nothing in this kit fits to anything on the car. I have fired the follow email to Tim. I dont know what to do here...


Hey Tim, I wish this email was being sent under better circumstances. I have been putting in your turbo system for the past Month now and for lack of a better word I feel let down here. While the turbo system fits great with its self, the components that have to be mated to the car have not fit. I have had to get the Exhaust manifolds machined ( The bolt holes on the manifolds did not even line up into a straight line). The down pipes sit way to high to be fitted with any kind of exhaust ( They sit about 1 1/2 -2 ' above the Y pipe connection, I will have to get a custom Y pipe fabbed). The welds on the intercooler are off again by about half inch, the bolt holes on the oil collector that sits under the transmission were again off by half an inch. The spacer that was supposed to come with Kit for the intake manifold did not come either, however I ended up going with a different manifold so it is not that big of a deal.

I just have to tell you I feel very drained and kind of beat trying to put this kit onto my car. Especially when so far nothing that was supposed to fit has.

 

ya, its definitely not a kit for the normal DIY. There is alot of at home tweaking. I was just goin to post, make sure you grind you steering knuckle bc it will hit the headers when you mount the turbos.

be interesting to see what he says.

 

When i mount the drivers turbo ill get that, I had to remove the whole lower column to put in the headers not looking forward to have to take it out again

 

i cant remember if you are 6mt or not, but if you are, be 100% sure thats the clutch you want in there. There is no way to drop the tranny without taking off the turbos., wastegates etc (basically undoin the install).

def easier with the motor out

 

Yes I am 6mt, this is the clutch i want for now, i plan to upgrade everything in a year or two when i do the engine.

However here is the response Tim gave me... Better then what I was expecting:



Hey Tim, I wish this email was being sent under better circumstances. I have been putting in your turbo system for the past two months now and for lack of a better word I feel let down here.

I am sorry to hear you say this.Maybe I can help?

While the turbo system fits great with its self, the components that have to be mated to the car have not fit. I have had to get the Exhaust manifolds machined ( The bolt holes on the manifolds did not even line up into a straight line).

I understand,we did get a bad batch of flanges and although they fit on our jigs,we didnt realize that they wouldnt bolt up easily to the heads so I do apologize for this.Had we known,we would have machined them here before they left but we only found out as we were called by a couple customers.Again,very sorry about this.

The down pipes sit way to high to be fitted with any kind of exhaust ( They sit about 1 1/2 -2 ' above the Y pipe connection, I will have to get a custom Y pipe fabbed).

I have never heard of these sittign too high before! The two bolt flanges on the back of the downpipes should be about 1/2" from the unibody? Is it closer then that? If the downpipes were 1-2" lower,you would not have any ground clearance.LOL.

The welds on the intercooler are off again by about half inch,

Do you mean the mounting brackets? The lower mounting brackets should line up easily where the threaded inserts are on the lower radiator core support.The upper mount should line up easily and bolt right to where the hood latch is attached.

the bolt holes on the oil collector that sits under the transmission were again off by half an inch.

Do you have a six speed or automatic.the bolt hol locatiosn are different for the two trannies and we could have potentially sent you out one for an auto or visa versa.

The spacer that was supposed to come with Kit for the intake manifold did not come either, however I ended up going with a different manifold so it is not that big of a deal.
>
> I just have to tell you I feel very drained and kind of beat trying to put this kit onto my car. Especially when so far nothing that was supposed to fit has.

Well I wish you would have called me my friend.We could have tried to help you over the phone or even sent out some replacement parts if neccessary.Also some pictures of what you arte dealign with would be helpful as some of the things you have mentioned to me not fitting,we just have never had any issues with.So if you can take some pics,that would be great.

Tim

 

ya Tim is pretty good about helping out, just takes a while for turnaround

 

On a side note, where should i move my powersteering cooler?

and Any suggestions on this

 

you move that last after you have everything else mounted.

 

In regards to the second photo?

 

I just unbolted my powersteering cooler, removed the brackets and ziptied it up and away so my intercooler could fit. I have a pic but it's on my other computer. I'll post it when I get home later tonight.

 

Power steering:






I drilled a couple of holes in the front plastic radiator support for zip ties. Worked out well.

 

I shortened my pipes and mounted on the brace bar

 

Had a few hours free today so I decided to do the following
Decided to remove the windshield washer fluid reservoir

Mounted the cosworth to the car

.. no issues but I did need one of these



and holy crap look at everything that has come off the car already

 

Any progress on the install are the turbos and manis on? It looks like due to the fact you found the the down pipe and the Y pipe issue? Any predictions on a completion date?