1.8 Turbo Build - Project Turbo - Chevy Cruze OT... Kinda

[Crewz]

Hey Gang,

Matt here. I just want to share my 1.8 turbo build / install. It's going in my Chevy Cruze, but it's the same engine as in the Sonic.

List of parts I have, and chances are I will be installing everything this weekend. Fingers crossed. BTW, if you would like I could share links to the things I got to bolt this thing up so you can duplicate this build. This is very much a budget build.

Part's list:
Ebay T04E internal wastegate Turbo
Universal black 2.5 intercooler kit with intercooler
HKS BOV matte black
K&N Chinese air filter knockoff
Chevy Cruze / GM 3" pipe with MAF flange
4AN oil feed / 10 an drain kit
Custom turbo manifold, log style with T3 flange. Bought a closeout ZZP SS flange and just used some stainless steel tees and 90º elbows.
2.5" universal exhaust kit
FlowMaster FX straight through muffler
Assorted flanges to assemble the exhaust
Turbo blanket / exhaust wrap
HP Tuners w/ AEM X Wideband for tuning
Semens 60# injectors from ZZP

I may have missed something...

The current plan is to add the turbo, and run it off the stock waste gate, which is set to 7psi. I'm new to tuning, so I've been doing my homework.

Future plans are to get a junkyard motor from LKQ ($249 + core charge), install a set of forged MaXpeedingrods connecting rods for a 1.6 Opel Astra... same rods in their 1.6, and I have a buddy, that has a friend (yeah I know) that has a custom dragster shop that can CNC some custom forged pistons for me. If that becomes too much of a pulling favors situation, I'll just go to JE Pistons for a custom set.

Target HP goals with the 7psi of boost, 175-200 whp. Once I have the turbo dialed in, which will take some time, I'm going to build up the built engine, and drop that in with a clutch that can handle the power. Manual trans build here. Then max out the boost. Final HP goals are 400-420.

 

[Crewz]

I'm pretty keen to taking photos, and posting my builds, but this time around I figured I'd do video. Here's part one, just going over the turbo I got and a few parts.

https://youtu.be/DIOYYX9HFIw

 

[Crewz]

Part two, more parts, and picturing how this thing will live in the engine bay...

https://youtu.be/wrjw7s-ctYY

 

[Crewz]

Starting the manifold build, and mocking things up... Did I mention this is my daily driver?

https://youtu.be/qJ_dk3g_s2g

 

[Crewz]

I decided to take the manifold off and mockup the turbo manifold bolted on, which was necessary.

https://youtu.be/VEWmH85AScU

 

[Crewz]

Last but not least, the finished manifold with some porting. I'm by no means a pro, but know my way around some basic tools. Thanks shop classes!

https://youtu.be/s_OTzT9Fo3E

 

[Crewz]

A few pictures of the turbo and manifold

Here are a few pictures during the mockup stages.

 

[TurtleOverlord]

I'll be following this, I have a bunch of parts as well but haven't gotten around to working on it.

Partially because its a daily, partially because of the tuning hassle.

Youll need a map sensor off a 1.4, the 1.8 only goes up to atmospheric.
I think an air temp sensor right before the throttle body.
A pcv reroute, similar to the fix kit offered on cruzekits.com.

are you planning on wiring the wastegate (eventually) and air temp into the factory ecu?

 

[deaven11]

good stuff here

 

[2015sonicspin]

Look overseas Z18xer pistons a lot cheaper and easier that getting some made

 

[Crewz]

I'll be following this, I have a bunch of parts as well but haven't gotten around to working on it.

Partially because its a daily, partially because of the tuning hassle.

Youll need a map sensor off a 1.4, the 1.8 only goes up to atmospheric.
I think an air temp sensor right before the throttle body.
A pcv reroute, similar to the fix kit offered on cruzekits.com.

are you planning on wiring the wastegate (eventually) and air temp into the factory ecu?

I hear that. Mine is my daily as well. I spent the Memorial Day weekend working on it. Thus far I have the manifold installed, turbo installed, I made a custom exhaust from the turbo all the way out the back...

I had hoped this would go a little faster, but working on a custom 2.5" exhaust on the ground, is exhausting... no pun intended.

I'll let you know more as things unfold. HP Tuners came in Saturday, but haven't even got far enough to play with it. Thus far I basically have a turbo on the exhaust and the stock air box. I took it down the road, and it sounds so cool. The turbo starts spooling around 2.5 RPM. My hold up ATM is the oil feed line is leaking and I kinda messed up with the rear exhaust. I'll explain more and get some pictures and video up, but I'm sunburned, worn out, and just wanted to touch base and give a written update.

 

[Crewz]

good stuff here

Thanks!

 

[Crewz]

Look overseas Z18xer pistons a lot cheaper and easier that getting some made

I'll look into it. I appreciate it.

 

[TboneMinister]

Wow, this build is really taking off! You've accomplished more in a few days than I've seen 1.8 turbo build threads accomplish in months.

 

[Crewz]

Wow, this build is really taking off! You've accomplished more in a few days than I've seen 1.8 turbo build threads accomplish in months.

Thanks! Has anyone completed a 1.8 build? I've only found one write up and they're somewhere in Central America I believe.

 

[Crewz]

So here are the money shots. Right now, the turbo is bolted up, full 2.5 custom exhaust with a high flow cat and FlowMaster FX straight through muffler. Sounds awesome, make turbo whines. The T04E starts to spool around 2,500 - 3,000 rpm, which is perfect because keep my daily driving under that.

I have a glorified hair dryer on it at the moment. Next step either install the #60 fuel injectors, and tune then charge pipe, or I'll install the charge pipe and adjust the waste gate so it's wide open and doesn't produce boost.

Once I get a moment I'll upload video that documents how I installed it, and what issues I ran into.

 

[TboneMinister]

So here are the money shots. Right now, the turbo is bolted up, full 2.5 custom exhaust with a high flow cat and FlowMaster FX straight through muffler. Sounds awesome, make turbo whines. The T04E starts to spool around 2,500 - 3,000 rpm, which is perfect because keep my daily driving under that.

I have a glorified hair dryer on it at the moment. Next step either install the #60 fuel injectors, and tune then charge pipe, or I'll install the charge pipe and adjust the waste gate so it's wide open and doesn't produce boost.

Once I get a moment I'll upload video that documents how I installed it, and what issues I ran into.

Do you plan on rerouting the intake for the turbo once everything is permanent?

 

[Crewz]

Do you plan on rerouting the intake for the turbo once everything is permanent?

I do. For now I just need a way to filter the air coming into the turbo. The plan, if I have the room with the charge pipe, is to point the 90º elbow down and get the air filter closer to level with the bottom of the car. Or I could possibly fab up something custom to get it stealthily pointing in the front bumper. Like where the fog lights would be on an LTZ model.

 

[TboneMinister]

I do. For now I just need a way to filter the air coming into the turbo. The plan, if I have the room with the charge pipe, is to point the 90º elbow down and get the air filter closer to level with the bottom of the car. Or I could possibly fab up something custom to get it stealthily pointing in the front bumper. Like where the fog lights would be on an LTZ model.

What are you going to do with the SAB/location?

 

[Crewz]

What are you going to do with the SAB/location?

What is the SAB? MAF?