5A-FE TURBO INTALL
Basically, I did alot of reading, and alot of internet research. But anyway on to how its done. First off, how much boost do I want? How much money am I willing to spend? Am I going to do all of the work? Where are the welding shops? What are the customs duties for car parts? (Just in-case you are like me and live outside the US). These questions have to be answered. Can the engine handle forced induction, yes but up a point. After 9 lbs alot of changes are required. I run 9 Ibs, currently and looking at achieving 15 lbs.
The first thing to do after all the previous questions are answered
is to get a Corolla manual, I got the Haynes Repair manual shown in
the pic.
Then get an engine compression tester, I got this one off of EBay.
The compression tester is to determine the status of the cylinders prior to installing boost and frequently after you've installed it, just to make sure things are ok.
If the engine fails the compression test then get it serviced
before continuing. The approx. specs for the cylinder compression is
listed in the manual. After this, then its getting the necessary
parts. Now my engine cabin is small and I didn't want to have to
move much stuff around, so I measured up the space available for a
turbo and manifold. Then it was off to the Math, calculations
necessary to determine the best sized turbo. With the dimensions and
the math, it was time to compromise. I ended up with a T20 up to T28
size turbo, (oil & water cooled) with a log style manifold that
would fit in the area without any work. (This Link
will give an idea of the turbo size)
My personal suggestion, in a country like Grenada, with not many
long stretches of road and lots of hills and corners; stick with a
small turbo, the quick spool and ease of installation is wicked!
Just don't expect much performance at top end versus say a Mivec, Levin or
Civic.
Ordering: EBay for most of the parts, except the turbo!@@#@# Can't
stress this enough! NO EBAY TURBOS!!!
Intercooler - Get it off EBay and get one with all the plumbing
(check out the main page for the link) - About 150 US plus shipping.
(ask for a discount you may get it)
Water Injection - Either get it off the guy's EBay store or buy
directly from the site - About 270US plus shipping (ask for a
discount, you may get it)
Now the turbo and most of the parts I got directly form Turbo specialties. The don't have a product for the 5A-FE engine, but most of the 4A and 5A are interchangeable. But you can get the parts elsewhere if cheaper. I highly recommend getting the turbo and manifold from them however, as it saves you the headache of making one and then fitting it to the turbo. Cost about 810US plus shipping. The turbo is a Garret and it comes with the manufacturer's warranty. The manifold is cast iron and really sweet!
Adjustable Rising rate fuel pressure regulator and map unit. These are about as important as the turbo itself. The Adjustable Rising rate FPR, is the poor mans solution until an e-manage unit and GT fuel rail + bigger injectors are purchased. The map unit again is available many places, and you have several options here; you can get an MR2 map sensor, the electronics are about the same, (slight mod may be necessary) or you can get a restrictor so that the map never sees the boost, but then you'd have to tinker with the fuel pressure. The safest option is the map unit from TurboSpecialties.
A torque wrench, usually available at your local hardware store
is also a must. It used when during the Head Gasket changing.
Because of the boost. Tightening the head bolts more than the
requirement help.
More to come...
PICS -
I haven't finished sorting them out, labeling and what not,
but here's a peek anyway.