Installing a 1.8t Big Turbo: Complete Guide to Apr Stage 3 Setup with Turbosmart Wastegate

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Upgrading your vehicle’s turbocharger can significantly enhance its performance. In this guide, we will cover the complete process of installing a 1.8T big turbo, specifically focusing on the APR Stage 3 setup with a TurboSmart wastegate. This upgrade is ideal for those looking to boost their vehicle’s horsepower and torque while maintaining reliability.

Understanding the APR Stage 3 Kit

The APR Stage 3 kit is designed for 1.8T engines and includes everything needed to maximize performance. This kit typically features a larger turbocharger, upgraded fuel injectors, and a high-performance intercooler. The TurboSmart wastegate ensures optimal boost control, which is crucial for maintaining engine health.

Required Tools and Materials

  • Socket set
  • Torque wrench
  • Pliers
  • Flathead and Phillips screwdrivers
  • New gaskets
  • Silicone hose clamps
  • APR Stage 3 kit
  • TurboSmart wastegate

Preparation Steps

Before starting the installation, ensure that you have all the necessary tools and materials on hand. It’s also important to work in a clean, well-ventilated area. Follow these preparation steps:

  • Disconnect the battery to prevent any electrical issues.
  • Remove the engine cover and any components obstructing access to the turbo.
  • Drain the coolant and oil to avoid spills during the installation.

Removing the Stock Turbo

To install the APR Stage 3 turbo, you must first remove the stock turbocharger. Follow these steps:

  • Unplug any electrical connectors attached to the turbo.
  • Remove the intake and exhaust pipes connected to the stock turbo.
  • Detach the stock turbo from the manifold and carefully lift it out.

Installing the APR Stage 3 Turbo

With the stock turbo removed, you can now install the APR Stage 3 turbo. Follow these instructions:

  • Position the new turbocharger onto the manifold.
  • Secure the turbo using the provided bolts, ensuring they are torqued to the manufacturer’s specifications.
  • Reconnect the intake and exhaust pipes to the new turbo.

Installing the TurboSmart Wastegate

The TurboSmart wastegate is crucial for managing boost levels. Here’s how to install it:

  • Remove the stock wastegate from its mounting position.
  • Install the TurboSmart wastegate, ensuring it is properly aligned.
  • Connect the boost reference line to the wastegate.

Upgrading Fuel Injectors and Intercooler

To support the increased airflow from the big turbo, you must upgrade the fuel injectors and intercooler. Follow these steps:

  • Remove the old fuel injectors and replace them with the new ones from the APR kit.
  • Install the upgraded intercooler, ensuring all connections are secure.

Finalizing the Installation

After installing all the components, it’s time to finalize the installation:

  • Reconnect the battery and all electrical connectors.
  • Fill the engine with oil and coolant.
  • Double-check all connections and fittings for leaks.

Tuning Your Vehicle

Once everything is installed, your vehicle will require tuning to ensure optimal performance. This step is critical to prevent engine damage and maximize power output:

  • Visit an authorized APR dealer or a professional tuner.
  • Install the APR Stage 3 software to match your new hardware.

Testing and Troubleshooting

After tuning, it’s essential to test your vehicle to ensure everything is functioning correctly:

  • Check for any leaks in the intake and exhaust systems.
  • Monitor boost levels and engine temperatures during a test drive.
  • If issues arise, consult your tuner or mechanic for troubleshooting.

Conclusion

Installing a 1.8T big turbo with an APR Stage 3 setup and a TurboSmart wastegate can significantly enhance your vehicle’s performance. By following this guide, you can ensure a successful installation and tuning process. Always prioritize safety and consult professionals when necessary to achieve the best results.