This install was brutal. But after a huge number of hours, I have finally figured out what turned out to be the ultimate Rubic's cube puzzle of a turbo kit. Here are some pics and details!
I picked up a used undivided ETS 321 stainless T4 manifold which only required me to modify the length of the actuator arm on the SP valve, instead of making extensive modifications to a divided manifold like the eBay ones. This HTA GT35 turbo uses a custom machined Garrett .84 T4 turbine housing which sinks the center CHRA deep into the turbine. This causes all sorts of interference between the turbine, bolts, and the water and oil lines, making it almost impossible to install. I assume this is because the GT35r was originally designed for smaller T3 turbines.
I had to source and cut-to length super low-profile button head bolts for the tubine housing.
I also had to go to a machine shop to have them weld on an allen head and shave off the edges of the bolt head on one of the cooling line banjo bolts, to clear the turbine. I also had to cut it shorter. My hacksaw was used on several various bolts during this project!
Otherwise I would have had to bolt the water line on first then clock the turbo on the turbine, but this made it impossible to tighten this little black bolt.
Still after all that I had to bolt the turbo to the manifold outside of the car, and install it and the manifold as one assembly, because there is simply no way to properly tighten the bolt directly under the drain flange, which itself can only be installed out of the car...!! To do this I had to cut my manifold head studs shorter and bash in one of my AC hardlines to clear. I had to create and buy a couple of custom tools to finish the install.
This bolt had to be dropped in before the oil drain was bolted on:
The clearance is ridiculous. I had to cut one of my allen wrenches short to get in here, as well as file this bolt head down and buy a stubby wrench specifically for it:
Installing the oil drain required removal of the compressor cover:
Luckily I had a baby sized crescent wrench to tighten this bolt.
Both the manifold and turbo needed a a fair bit of griding to match the SP valve T4 ports and to clear the valve itself when opening. I also spent some time grinding down the inside of the manifold collector so that the 3 cylinders on the front of the engine wouldn't have to squeeze through such a tight opening. It is now about equal for all cylinders.
Two post-turbo boost sources. One goes to the solenoid to the valve, the other goes to the hobbs switch which I can set to any psi I choose. (Yes I used thread sealant
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After all this trouble, I now REALLY see the merit of bolt-on kits!