Here is a write up on how to install the buschur unit on an evo. This write-up is provided by Dynoflash www.dynoflash.com, if you have any questions feel free to email me at aaron@dynoflash.com.

We took the buschur kit and received it on Friday. here are some snap shots of the setup, this is the br 440 kit. Which is apparently a GT32 Turbo, with a .70 a/r. (all the specs i can find on the turbo)

 

First we took off the heatshield, and sprayed some 3M Penetrant on the bolts, this will make them like butter to remove!



Then we unbolted the radiator


Next start disconnecting the intercooler hoses, we did this to give us plenty of room





Next we removed the induction tube, from the HKS RS intake



Now on to the Radiator!

 

Hop under the car and disconnect the lower radiator hose. Make sure you have something to collect all the anti-freeze.




Then disconnect the top radiator hose, we did the bottom first because once you disconnect the top, alot more fluid sprays out. so don't remove the collection method under the car.



Then tuck the radiator hose out of the way. The upper intercooler hose works great!



On to the Oil!

 

Next drop the oil, make sure you collect it and dispose of with in EPA regulations. Remove the filter also, you might as well because your gonna want to drain the oil. because you need to tap next to the filter for the new turbo oil feedline.

Once you have drained all the oil. Disconnect the banjo bolt on the head, that runs to the oil feed line to the stock turbo. Have a paper towel handy to wipe up the little bit of oil that will come out. Your going to want to put the plug that buschur supplies with your kit in the place of the banjo bolt. You will have to bend the feed line a little bit to get it out of the way.



Next your gonna remove the coolent lines to the stock turbo. these are the lines pictured below in the center, one is brass colored the other is silver




Next move the return line up and around so you can connect the feed line to it




Now pull the radiator out so you can have some room, and set it aside becareful as there is still some fluid in there and you might not want to spill it, Rememer to disconnect the fan relay, so you can pull it out.

Then remove all the nuts holding the manifold. you will need a 12 mm and 14 mm socket. The inner nuts use a 12 mm, and the 2 far outside nuts, far left and far right, are 14 mm. There are 2 on the under side that you will need to hit from under the manifold.

There is one bolt on the underside of the turbo that needs to be removed, it holds the turbo up. While your under there, take a 10 mm with you so you can remove the Oil return line off of the Oil pan.

Now open up your Spark plug cover, it has the MITSUBISHI on it, and disconnect the o2 sensor, we found it easier just to pull the turbo out with the o2 Sensor attached, then remove it.

Now you need to disconnect the downpipe from the o2 housing on the turbo.

Now you can pull the entire setup out.

 

Next remove the bolt that is next to the oil filter location, your going to need an allen socket or allen wrench, this thing is going to be in there tight so your going to need to use some brute force becareful not to let the socket slip. Have the oil catch underneith, as you will find more oil there!

Then place the new setup that buschur supplied you with.



Make sure its tight and face it toward the front of the car, and run the feedline next to the oil pan.



Zip tie it up top, to keep it in place while you get ready to put the turbo kit in.

Now place the new setup in the car, We used a bolt to hold it there while we connected the return line and feed line. For the oil return line we cut the stock one off at the bottom of the ribs, as buschur doesn't supply a solution for this, with this done, you will have plenty of room for the new return line.





Next connect the oil feed line and the o2 sensor, you can also bolt up the downpipe.

 

Next you can run your boost line to the wastegate. You need to also connect to the other side of the compressor housing, you can see the nipple in the bottom of the picture.



and now your ready to put everything tighten down the nuts on the new manifold, i would recommend you don't tighten any of them until you have them all on. do the bottom ones first, if you have a grinder, you might want to make a little room under the holes on the manifold, as the stock nuts do not fit perfectly, they fit, but because of the rim on them, they will be a little hard to tighten down.

Once we got all the nuts onto the bolts, we tightened the underside first, all three bolts, these were done by hand with a 12 mm wrench, have patience during this, as its not very fun!

next we tightend the top two center bolts and then preceeded outside to the 14 mm bolts.

Now you need to connect the Stainless tube that buchur supplied to the compressor housing, to the buschur intercooler. If you don't have a buschur intercooler your going to need to fandangle it a little, you'll need a bender and or other methods your on your own if you don't have the buschur intercooler.

Now you put all the other things back, radiator, upper intercooler pipes, air intake ect.

 

The fan is a different story all in its self, your gonna need to use the fan buschur supplied, however, this is gonna take some "jimmy rigging", its not hard, and you'll see it once you lay the fan out...you'll need to cut the plug off the stock one, and splice the stock connect onto the Spal fan, and then zip tie the fan rely to the housing of the Spal fan. do this before you put the radiator in. Again if you have questions, feel free to email me. and i can answer any of your questions.


Here are the final install pictures

 

the wastegate's thresh hold is 15 PSI, so make sure your boost controller is reset...

 

nice write up...... now its time to go get a MR DV/bov so it can handle the boost

 

yeah, i should have snapped a few more pictures, but yes i'm gonna find a new bov well recirc

 

Great job let us know how it runs....

 

it runs great! spools a little slower, but much more powerful

 

Thanks for the write up man

 

Great writeup Nastea. Can you give us more details on the results. Spoolup? Powerband? ..... or you waiting to have Al tune it?

 

spool up as it stands right now is full boost by 32-3500 depending on gear, it hits a full 20 psi by then