TPC Racing ATP:2 turbo kit DIY Install
 

Well the install of the TPC Turbo kit is finally on it's way. Cheerio's shop has been tied up, so finally got it cleared out last night and we took the time to unbox and put everything on a work bench, plus set out all the tools we need so the install will be a much smoother process. We should have the car on the lift today, and well have more pics and info to share as we progress on the install. So check back soon!

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Can't wait to see the full install!!

Ok here's a little update from today. Thanks again to Cheerio for the help with the shop, also MoWilson329 for coming out for the support and help! We started in the afternoon and only got about 4hrs into the install but I think we got a lot done. Everything went pretty smooth so far, hope it keeps going that way :)

Ok on to some pics from today. Here's Cheerio and MoWilson329 arriving at the shop.

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One bad thing with having a car that's slammed is getting it on the lift lol.. We had to drive the car on to wood blocks be able to swing the lift arms under the car.

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Once the car was on the lift we disconnected the battery:

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Bumper is off so we can get access to the 3rd radiator which will now be used to cool the water/air cooler:

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Next all the under panels has to be removed to be able to snake the new coolant pipes to the 3rd radiator:

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Out with the Tubi.. My lucky brother wil be getting this :) I am going to miss the sound from it though :(

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Once the exhaust is out of the way we removed the brackets holding the exhaust in place:

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We also had to loosen the lower beam to be able to remove the under panel:

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Rear under tray slides out after removing the 6 bolts holding it in place, we will need to modify this later on to attach the water and oil pump supplied with the kit:

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Next we move on to removing the intake box, which I was told is pretty much the most difficult part of the install:

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The OEM needs to be removed, so once all 4 clamps are loosened and the throttle body detached from the intake hose, the whole unit will just slide out:

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Next the MAF and intake hose is removed by loosening the 2 hose clamps:

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Next will need to remove the left side fuel rail and intake manifold to be able to get the intake box out:

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Manifold is out of the way, but the intake box still cannot be removed yet...

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I know this is going to look rough, taking a saw like that on a car :-p but it went rather smooth. The intake box will need to be modified to fit the new setup, so we opted to cut the box and remove it in pieces:

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Here's what we have with the box and manifold removed:

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So that's it pretty much for today, it was dinner time so we decided to call it quits. Will continue tomorrow...

Here's a final image I wanted to share.. Cheerio, insisted on being neat and making sure every bolt was put into bags so we can identify where everything, when we bolt everything back up. So in the end if we have 1 bolt left over we failed :taunt:

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well, at least you dont have to worry about losing bolts, etc. and friend of yours did it for you so that's plus! :)

looks awesome donny. keep it up!

where does the tubo kit bolts on?

to the stock headers?
is it compatible with catless headers like this ?
http://www.fabspeed.com/images/Cayman_8_1.jpg

The turbo bolts on to 2 pipes that both come from either side of the exhaust manifold. Yes you can retain your stock manifold or go with any aftermarket exhaust manifold. Ill post pics up once I get to that step so you can better see hot the turbo system connects up.

Ok here is some progress from yesterday, doesn't look like much since its just moding the air box, and installing new spark plugs and mounting the oil pump.

So with the air box out of the car, we need to trim down the intake box to move the MAF sensor to the the inside of the box.. we started by cutting down the sides.

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We use a large 3 1/2" drill to drill a big enough hole to fit the maf sensor.

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Here's how it looks with the maf inside the box.

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Completed box

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Next we moved on to mounting the oil pump that will pump the oil from the turbo back into the engine.

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Here's the new pump mounted on the bottom tray

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Last thing we did for the night is unbolt the ecu which will be sent to TPC Racing to get it flashed.

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More to come..

Wish I have 1 too hilarioushilarious. Gonna be a blast.

nice, mad respect to a fellow do-it-yourselfer, I've done everything to my car myself too. The TPC kit is my next mod as well. Thanks for taking tons of pics too.

Thanks porsche4ed, yes like you I always like hands on project, and plus you save a bit doing everything yourself :)

Here are some pics and updates from last night.. I have to say it felt like the most productive night we had since most of the major components were bolted up and its finally starting to take shape..

We started with the water/air cooler setup.. The setup is help up in place by 2 bolts, but you will also need to push up the heat shielding to make room for it:

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The installed water/air cooler:

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Next we prep the turbo by installing the oil fittings/gaskets:

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The turbo/manifold bracket goes in place next:

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After that we install the 2 runners that connect to the exhaust manifold and collect at the turbo:

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Next step the turbo goes in place:

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A pic from underneath:

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Next item the exhaust goes on and is held on by the supplied clamp which attaches to the turbo's turbine side.

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We prep the external wastegate, by installing the supplied spacer/gaskets:

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Bolting it up to the system:

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Then if anything goes wrong you are familiar with the set up. :)

Almost there with the install. Day 4 and 5 was reinstalling the intake box, intake tubes, and installing new coolant hoses.

Intake box is back in place, it was actually kinda of a pain to get it back in there since there is so little room to work with. But lotsa wiggeling and it pops right back in:

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The driver side intake manifold goes back in to place:

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New coolant lines are installed next. I picked up special heat sleeve to protect the hoses from radiant heat, since it passes pretty close to the engine. The will be routed over the driver side intake manifold, and all the way to the front of the car:

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View of the lines passing the front of the engine, make sure you have clearance from all the belts:

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Routing in the front:

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I picked up these aluminum brackets from a member on the forum, to help route the new coolant hose:

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Out the front:

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The original hose coming from the 3rd radiator will be modified to fit the new smaller hoses:

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This is how it will look back on the car:

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Next we install the new oil vent that is routed to under the car:

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The new plenum from TPC Racing is reinstalled along with the throttle body:

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We move on to the intake hoses, starting with the hose connecting the turbo and the water/air cooler:

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