IC and K04 Big Wheel install - Pontiac Solstice Forum
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post #1 of 14 (permalink) Old 05-17-2019, 09:13 AM Thread Starter
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IC and K04 Big Wheel install

I'm going to start this project today, with the IC. If time, I'll start the turbo this weekend.

For those of you who've done it...any tips, tricks, etc? Especially anything about the R&R on the turbo. The IC seems pretty straightforward- just have to reshape the mounting bars for the air dam. I have have the DDM charge tubes (not pictured). Upgraded clamps long since installed on the factory charge tubes.

Solo high flow cat and street race exhaust already installed.

TIA.
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Last edited by lorennerol; 05-18-2019 at 10:26 PM.
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post #2 of 14 (permalink) Old 05-17-2019, 01:53 PM
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What are you planning on using the copper spray gasket for?

Blue-ish 2006 2.4, Werks stage 1 turbo, Borla cat-back, DDM braces, Spec aluminum flywheel, Spec stage 2 clutch, Werks aluminum radiator, some gauges, RKSport hood, Morimoto FX-Rs, GReddy Profec, Norm's fenders

'07 GXP, RPM Stage 2, Solocatless downpipe, TCE Wilwood 6 piston front brakes, 4-piston rears , Stainless brake lines, slotted/drilled rotors, BC Racing BR coilovers, Performance Autowerks intercooler, DDMWorks CAI, charge pipes and braces
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post #3 of 14 (permalink) Old 05-17-2019, 05:12 PM
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-Raise the engine from the passenger side as high as possible!!!!

-Several nuts on my exhaust manifold where really loose, so don't forget to retorque the exhaust manifold nuts!!!

-Use plenty of wd40!!!
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post #4 of 14 (permalink) Old 05-17-2019, 05:18 PM
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You are missing a wastage actuator rod retaining "clip", it's purpose is to prevent the nuts to become loose, but you can install the turbo and later on install the clip
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post #5 of 14 (permalink) Old 05-17-2019, 07:01 PM Thread Starter
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Quote:
Originally Posted by SSolstice View Post
You are missing a wastage actuator rod retaining "clip", it's purpose is to prevent the nuts to become loose, but you can install the turbo and later on install the clip
Thank you. It actually has nuts on a threaded rod instead of a clip in slots in a smooth rod.

Appreciate you for noticing and saying something.
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post #6 of 14 (permalink) Old 05-18-2019, 06:25 AM
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Quote:
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You are missing a wastage actuator rod retaining "clip", it's purpose is to prevent the nuts to become loose, but you can install the turbo and later on install the clip
That clip was a production change. My early production GXP (#1,300ish) doesn't have one either.
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post #7 of 14 (permalink) Old 05-18-2019, 05:47 PM
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Make sure you don't have any metal shavings in that IC.

____________________________________________

Solo Street Race exhaust
Fujita CAI
ASAP T2 stripes and badging
Windrestrictor V2 lighted in white
Windrestrictor lighted door sills lighted in white
DDM Works IC Piping
Undercar LEDs in white to match Windrestrictor

ZZPerformance dyno tuned - 286HP, 317ft/lbs of torque at 23psi of boost.
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post #8 of 14 (permalink) Old 05-18-2019, 10:11 PM Thread Starter
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Old out, new in today. Got stuck (it was 8:00 PM and I was tired anyway) installing new DDM polished charge tubes. They came with new silicone tubes that are thicker than stock and the t-bar clamps I installed years ago to replace the OEM clamps are too small.

I have a set of articulating, ratcheting box wrenches that make a couple steps easier (looking at you, bottom inboard down pipe nut). As does a pneumatic or electric ratchet. Oh, and a parking lift. Jeebus, I can't imagine doing the underside work laying on my back. Kudos to those who have.

Oh, and the turbo that was on the car (built July 2007 as a 2008) has the same nuts as the one I put on, not a retaining clip.

Tomorrow I hope to find bigger clamps and finish up the charge tubes, get the front end back on the car, and refill the coolant. Any tips on that greatly appreciated- it looks to be a PITA without the special tools, which I'd be willing to buy if I can find.
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post #9 of 14 (permalink) Old 05-19-2019, 09:44 PM
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who's tuning your car?
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post #10 of 14 (permalink) Old 05-19-2019, 10:50 PM Thread Starter
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who's tuning your car?
Dave at Werks. I decided that would be best since the turbo and IC came from his shop.

I'll have some more photos on Tuesday after I get the M10-1 tap I need for the charge tube, the clamps, and the vacuum tool for refilling the coolant.
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post #11 of 14 (permalink) Old 05-25-2019, 10:32 AM Thread Starter
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Final fasten-down day, then load the first version of the new tune from Werks and off for a test drive.

Feels like Christmas morning!
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post #12 of 14 (permalink) Old 05-25-2019, 11:05 AM
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Final fasten-down day, then load the first version of the new tune from Werks and off for a test drive.

Feels like Christmas morning!
Great job on the install, I hope the test drive goes smoothly!
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post #13 of 14 (permalink) Old 05-25-2019, 02:46 PM Thread Starter
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Great job on the install, I hope the test drive goes smoothly!
Thank you. I hope I learned some things because we're doing my buddy's tomorrow

Only problem with the test drive is that a very light mist turned into rain and I had to cut it short. Not before I spun the wheels below WOT and saw it boost to 25, though. Tomorrow and Monday should be better for collecting some logs for Werks to chew on for v2 of the tune.
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post #14 of 14 (permalink) Old 05-25-2019, 09:44 PM Thread Starter
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Mechanically complete and test drive #2 in the books. It's running great. Can't wait for drier roads Sunday and Monday.
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