So the weather finally breaks here in Maryland and we have a nice 80 degree day. Great day for a turbo install. As some of you might know and most don't, one of the premire ZPI xB guys (proshopxb) sold his xB in exchange for a neon. well a neon with a turbo that is. As such I was fortune enough to get his turbo and parts from him.


This is the story of the install

2005 Scion xB manual transmission, 64000 miles. Only performance mods are a AEM CAI and a TRD exhaust.

Tools used.
10mm 12mm sockets. 15mm socket (exhaust), Flat head screw driver. Hex key set. Pick. Water (to drink)

Shots of the motor before hand. (yes I know its dirty)




What I will be working out of


Standard Valve Cover Cover. (4) 10mm bolts hold it on.



Grill removal: 3 clips hold it on across the top. Use pick to lift center then remove.



Front Bumper removal. Under the grill there is one more clip and two bolts. Remove then them. Then under the fender inside the wheel well there are two bolts. Remove the lower one. Under the car there are bolts that hold the splash guard down and to the bumper and the bumper to the fender liner. remove them and two square plastic clips.







To be continued .....

 

... Continued

Horn Removal. 1 bolt to remove, just set it aside.


Crash brace removal. 6 Bolts to remove.




FMIC mounting. Remove the plastic where the horn was and on either side of the car under the lights. Held in by 2 plastic squeeze clips. Remove the bolt holding the passenger side of the AC condenser. Mount IC on and resecure using previously removed bolts. You can at this time reinstall the horn into its previous spot.






Piping install. Remove previously installed intake. Disconnect and remove MAF sensor.






Install Piping Couplers and route piping. Passenger side behind fan, driver side to throttle body. Secure all couplers with hose clamps.






To Be Continued ....

 

Continued....

Reattach the crash brace


Secure the IC piping to the throttle body, and reattach MAF sensor. You can also see where I installed the oil pump.


Here is where I made a side track

Build the turbo setup
Attach Air Filer, Exhuast pipe, Waste gate, IC pipe, Oil Feed and return line tips. You can losen the clamp on the turbo to allow it to swivle if need be. use supplied bolts and gaskets when attaching.












Valve cover removal and replacement.

I was supplied a pre tapped valve cover for oil return. Sorry the pics are in reverse I forgot to take them before I took off the Valve Cover. Yes I know I need an oil change. Be sure to use new gaskets when performing this task.

There are several bolts and nuts that surround the valve cover that need to be removed. There are two bolts in the middle of the cover and all coils need to be removed also by removing the 10mm bolts on each of them. Don't forget to mark them 1 -4. So you know the order they go back. There is a wire harness on the passenger side you will need to move and remove its bracket in order to get to a bolt.












So Ends Day 1 of my ZPI Turbo install


To be continued.........

 

sweet dude! Nice pics cept for the last like 6 are just x's but anyways nice job looks good hows the power?

 

Do you think you could resize those pics, they are huge and could take forever to download. Looks like you're on your way though...congrats!

And just out of curiosity, what camera?

 

DUDE! DSL is going to have problems loading this! LMAO

 

after u load em once, its not bad, im having no trouble on this page, and loving the big pics, lol.

 

I wanted that kit SSSOOO Bad and was trying to get the money together..soon as I did..you got it like 2 hours before me !! I hope it works out well for ya !! Congrats !!

 

Sorry about the pic size, just trying to do an indepth how-to at the same time. I could have gotten this installed faster if it wasn't for the fact I was stumbling through it and trying to blow up small pictures to see details.

Camera is a Nikon Cool Pix L6

Well off to start Day 2

 

sooooooooooooo damn lucky i was trying to get that setup from him too!

 

Gooood luck with the rest of the install! And nice camera.

 

Why did you have to remove the valve cover?? Did i miss something in the read?? BTW, your camera is DA $HIT!!

 

he got a valve scover with an oil fitting on it already, so he swapped it.

I don't know if ZPI includes instructions with thier kit, but i your doing an awesome write up for it! I'm keeping this handy

 

oh ok, i understand...

 

Awsome job so far Pat... Sorry I havent had a chance to PM you back yet with more help, work has been helacious.. But it looks like you are doing pretty good with out me.. Nice to see the old kit out of a box and on a box.. I will PM you tonight with some more answers to your questions.

 

OK so I took my car to a muffler shop to get the turbo welded on and they had so many problems that it took them a day to get it done. So I got it back and picked it up at 5pm after a nice Tweeter Mobile Training Session all day, so I was left with 3 hours of light to work with. Here are the pics, Hopefully on page 2.

 

Comeon Page 2

 

Oh and when ever you work with something under pressure, make sure you tighten it down REEEEEALLLY tight. I have to clean up a nice oil spill on my driveway from a not tight hose.

 

INSTALL DAY "2"

Ok me start by appologizing for the large pics again. But this is done to show detail.

First, this is why I love having an xB.



Exhaust.

OK here is some shots of my stock exhaust. First picture, from rear to front, left to right, the resisnator, rear o2 sensor, Catalytic Converter.


Catalytic Converter and header downpipe.


Shot from front, Transmission, Cat and resisnator.


Passenger side IC pipe


IC pipe from driver side view.


Now you might be asking what the hell was the point of all those pictures. Well, some people like my camera so I wanted to take more pics for them.

Accually its to prepare you for the next post.

To be continued....

 

Continued ....



Whats that?




Now remember how the stock exhaust looked? Well as it turns out, for this kit, the Catalytic Convertor had to be relocated since it cannot be removed legally. The reason was the Turbo sits where the Cat ought to. So I had the Turbo mounted to the headers, Cat relocated, since the cat was relocated, it replace my resisnator and the remaining space was taken up by straight pipe.




Money shot



We now return you to your regularly scheduled how to after the break.

To be continued.....