Out of the box the kit needs a little work.......
First of all the supplied stock Jspec manifold was cleaned up.
Next the turbo manifold has to be cleaned up inside as the weld penitration
causes major flow restrictions, great care must be taken not to weaken any joint.
Before:
After:
Now its time to strip the stock turbos off the car...
First put the car on an axel stand and remove the drivers side front wheel, this
will make life easier later.
Last chance to see it how Toyota intended.
Now start stripping the induction side down at the top.
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Thats about as far as you can get from the top for now, so its time to get under
the car and remove the 1st cat (decat pipe in my case)
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You need to undo the inner bolt that holds turbo 2's intake pipe from underneath, the outer one can be accessed from the top.
Also hard to see but accessed from the top are 2 bolts that hold the coolant
pipe in place, seen here on the removed intake pipe.
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Then its back to stripping the rest of the intake piping off the top
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Now its time to remove the front turbo, This will give you access to all the manifold nuts. Note there are 6 nuts that hold it to the down pipe and 4 that hold it to the exhaust manifold.
Also holding the turbo on are the water oil feed pipes, the oil being hardest
to get at under the turbo.
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Now the back turbo the downpipe and exhaust mainfold can be removed in one piece, the exhaust manifold nuts are very tight, lots of WD40 will help.
Don't forget the water and oil pipes!
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Now remove all the oil and water pipes from the block and thats the stripdown complete!
Now its time to start fitting things.
Some things can be fitted permemently and others just test fitted at this stage.
First things to be fitted are the new oil feed and return pipes.
On the auto you have 2 pipes in the way of the return, these can be gently bent out of the way and the return fitted.
The rear old feed then needs to be blocked with the supplied bolt and the new feed line attached to the front feed.
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Now test fit the manifolds, turbo and down pipe ready for aligning the hard pipes.
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After test fitting the ram pipe it was found to be far too long, so some had to be cut off.
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Heres the turbo with the elbow welded on and the maifold with the 1/8 NPT hole
tapped ready for the egt PROBE.
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The hard pipes with the take off pipes for idle speed control valve and BOV welded in place.
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The next problem was the J Spec downpipe flange is totally different to the UK one and meets it a different angle.
For scale, thats a 1/2 inch drive extension in the gap, the other side of the flange is almost touching.
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The solution was to take spare UK flange, bolt it to the cat replacment pipe, ling up the down pipe and fabricate a plate to fill the gap.
Tack it in place using a mig welder, then take it off the car to have it Tig welded complete.
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Turbo, manifold and wastegate assembled on bench (excuse the mess!)
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2 water pipes cut off, drilled out and tapped M12.
Sealed with grubscrews and locktite.
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The new home for the stock BOV
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Job done, for now, still a few things to be sorted out and tidied up, but thats basicaly how I did the job.
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