If you missed the first part of our GT28RS eliminator install, please read this before proceeding in this thread:
During our last episode, we were ready to bolt the turbo onto the manifold. In order to do this, you use and OEM 3 bolt ko3/04 gasket. The gasket looks like this:
Two gaskets that look identical, correct? Look again, as one is an OEM dealer gasket, and one is from an aftermarket supplier. We spread the gaskets apart, and they are both four plys:
However, a closer look reveals that the factory VW gasket has thicker plies, and is cut much smoother than the aftermarket unit. (OEM 4 ply unit on top, thicker rough-cut aftermarket unit on bottom):
Make sure that you use OEM quality gaskets, or request them from your preferred shop. We only use the OEM units after having failures with the non-OEM units.
Before we could mount the turbo to the manifold, we ran into another issue.The 90 degree fitting points directly at the coolant feed line:
Edit: As an additional note: The hardline fabrication below for the coolant line would not be necessary if the coolant line was run towards the bottom of the turbo. We elected to run it towards the top. Running it towards the bottom will save some time and fabrication.
You have two options to rectify this situation. The first is two shift the coolant fittings to the side, which we find unacceptable, as they touch the turbine housing:
To fix this issue properly, we fabricated a hard line and added a 45 deg fitting(instead of the 90 provided)
The hardline gives the added benefit of moving the soft braided line away from the manifold. We would consider this mandatory for a car that sees track usage. Street cars and drag cars would probably not need this modification, but this is at your own discretion.
With the hard line fitted, the vac fitting points in the wrong direction now:
There are two options to fix it:
Rotate the fitting:
Or cap off with a 1/8 pipe plug:
We elected to cap it, as the fitting was superfluous.
Here is another hardware tip. We exclusively use 2.7T S4 nuts on all of our installs. Here is a picture of the S4 nuts vs. standard copper nuts provided:
Use the S4 nut on the turbo to manifold stud(the nut is not stripped, it’s covered in anti-seize):
The coolant return line from turbo to the block is straightforward:
ATP was supposed to provide the studs which adapt from the 8mm threads in the turbo oil return flange, but they were missing. We prefer bolts anyway, but 8mm wouldn’t fit.
We drilled it out and inserted the bolts.
Here is the oil return line fitted. Straightforward, right? Not. (The gasket is misplaced in the picture, we know)
The oil return line does not clear the inner axle boot shield(which is mandatory for a track car. Bend the return line up to prevent this interference)
We needed to neck down the GHL 3” to mate to the 2.5” catback, so we welded on a 3” to 2.5” transition and stainless extension.
Here is the 3” GHL Downpipe mounted up(Note S4 nuts used again):
On to the modifications required to install the ATP big bore inlet, which are some of the more difficult ones in this install.
Before we can even install it, we need to work on the inlet. ATP inserts a bolt to close a hole in the big bore inlet. This is unacceptable:
We tapped the hole and inserted a pipe plug to open up the airflow.
There are two major issues with the ATP big bore inlet. This unused mounting hole on top of the tranny interferes with the big bore inlet:
We ended up cutting and grinding it flat so that the big bore could sit on the transmission properly:
Here is the shifter cable bracket provided by ATP to remount the shifter cables above the big bore inlet:
However, one of the shifter cables does not reach when mounted in the bracket.
The cable needs to be moved forward, but the bracket is not far forward enough.
Time to fab. Again. What else is new? Cut the offending piece off:
Weld in an extension:
The speedo sensor hits the big bore inlet silicone. Just rotate it out of the way:
Part III will be coming in another 1-2 weeks, as we try to finish this off and actually start the car…..
Modified by tyrolkid at 7:14 AM 9-6-2006