I'm at a loss...

[Toddasaurus]

Don't forget this little bolt for the coolant hard lines...


And the primary o2 harness plug!



Now the turbo heat shield. One of the three bolts is a pretty dang annoying to put in, but it's nothing compared to the turbo oil drain line bolts!



Now time to go underneath the car again and attach the secondary o2 sensor plug and bolt the bracket to the firewall.



And finally, the downpipe stay bracket.





Before I forget, gotta put this plastic shield back in as well...

 

[Toddasaurus]

Last thing for the night was the midpipe. Installation is pretty easy, IF you do it in the correct order.

First bring the front of the pipe up around the downpipe and let it rest on the subframe. Next, line up the back end of the midpipe to the rest of the exhaust. Don't forget your gasket!


Now, the midpipe will be held up by the back 2 studs, and the subframe will hold up the front end. This will free up your hands so you can install the stay bracket.



Remove the bracket bolts from the transmission, then line up the holes to the midpipe, and reinstall the bolts to the transmission, but don't torque them completely. Then install the bolts on the midpipe that connect to the bracket. Again, don't torque them down completely, as you may need a little wiggle room to line up the front and back of the midpipe flanges.



Now you can easily line up the front, and install the two 19mm bolts.



Torque down the two nuts on the back end of the midpipe.



Finally, tighten all the transmission to midpipe bracket mounting bolts.

 

[EdP]

5th

The excitement builds!

 

[Toddasaurus]

The last thing I did for the night was just to attach the 2 coolant hoses to the coolant hard lines.





At this point I called it for the night, as I wanted to spend some time with the family! Here is the pile of stuff still needing to go in - almost there!!!



I should be able to finish reinstalling everything today, and then I'll fill it with coolant, bleed the air out, and start her up!!!

 

[Husky]

Don't forget this little bolt for the coolant hard lines...
View attachment 23531

And the primary o2 harness plug!
View attachment 23532


Now the turbo heat shield. One of the three bolts is a pretty dang annoying to put in, but it's nothing compared to the turbo oil drain line bolts!
View attachment 23533
View attachment 23534

Now time to go underneath the car again and attach the secondary o2 sensor plug and bolt the bracket to the firewall.
View attachment 23535
View attachment 23537

And finally, the downpipe stay bracket.

View attachment 23538
View attachment 23539


Before I forget, gotta put this plastic shield back in as well...

View attachment 23540
View attachment 23541

Bravo! You certainly got a lot done (and documented). Very well written and photographed Todd. You could produce your own assembly manual. Actually, you made it all look pretty easy, I don't know what all the flap was about .
You know I'm kidding.
Can't wait to hear you've got her running again.

 

[pulsar]

Todd, great pics and story along the way. You showed your torq wrench and it had what looked like a calibration sticker on it. I work in an Aerospace factory and every tool we use is calibrated. I have several Craftsman torq wrenches at home and have periodically brought them to work and validated accuracy. Never officially calibrated them though and I do zero them out after use. Was yours actually calibrated with an expiration date? If so, you be the first DIY person home mechanic I’ve known (at least via this forum) to go to that trouble. Puts you way above most of us in being very thorough and complete. Based on the job you have done at hand, your easily at or above any dealer certified mechanic by a good margin. Can’t wait for final chapter and engine start and leak test.

 

[mrcleeaan]

Todd, you are an absolute beast to be able to accomplish all this (removal/install, high quality pictures, documenting everything) on your spare time! I applaud you sir!

 

[Toddasaurus]

Todd, great pics and story along the way. You showed your torq wrench and it had what looked like a calibration sticker on it. I work in an Aerospace factory and every tool we use is calibrated. I have several Craftsman torq wrenches at home and have periodically brought them to work and validated accuracy. Never officially calibrated them though and I do zero them out after use. Was yours actually calibrated with an expiration date? If so, you be the first DIY person home mechanic I’ve known (at least via this forum) to go to that trouble. Puts you way above most of us in being very thorough and complete. Based on the job you have done at hand, your easily at or above any dealer certified mechanic by a good margin. Can’t wait for final chapter and engine start and leak test.

Unfortunately I cannot take any credit related to calibration of the torque wrench. It came with the calibration sticker on it! Even so, thank you for your kind words!

Just bought some OEM Hyundai coolant. Will mix 50/50 with distilled water for refill. I decided not to re-use the original coolant I drained. I'm sure it would be fine, but, well, may as well go with new!

 

[OMG70]

Unfortunately I cannot take any credit related to calibration of the torque wrench. It came with the calibration sticker on it! Even so, thank you for your kind words!

Just bought some OEM Hyundai coolant. Will mix 50/50 with distilled water for refill. I decided not to re-use the original coolant I drained. I'm sure it would be fine, but, well, may as well go with new!

Don't forget to huff it like your windshield washer fluid

 

[tuckerdog1]

I started a trip the day before Todd's 1st post. Just returned, saw this thread & read every post. I got sucked in. Reads like a thriller novel. Can't wait for you to cross the finish line. Bravo sir, you are an inspiration.

Tuckerdog1

______________________________

Help support this site so it can continue supporting you!

 

[Beefer]

I started a trip the day before Todd's 1st post. Just returned, saw this thread & read every post. I got sucked in. Reads like a thriller novel. Can't wait for you to cross the finish line. Bravo sir, you are an inspiration.

Tuckerdog1

Yeah...especially the blood. He says it's from his fingers...but I think he started head butting the turbo out of frustration

 

[FastEddie]

Yeah...especially the blood. He says it's from his fingers...but I think he started head butting the turbo out of frustration

I think it’s a blood oath he made with his car not to f$%k with it anymore.

 

[DSXMachina]

The only down side to this saga which Todd has so well documented is that when he's done...the car will be no better than before he broke it. Been there. Done that. More than once.

 

[Toddasaurus]

Okay, had some time right after work to put almost everything back together. Here goes.

First had to reinstall the throttle body. But before doing so, I previously noticed some weird glu-like droplets spackled all around the inside of the throttle body. I figured I'd clean it out, so I had a tiny bit of carb cleaner left over, sprayed it on a shop towel, and wiped the inside relatively clean. The throttle butterfly still had some black overspray looking material on it, but it was smooth, and it looks like that really is overspray from the factory. *shrug*

Before...


After...


Throttle body installed. Don't forget those coolant lines.




Now time to install the intake piping. First, put on the hot side charge piping coupling coming straight off the turbo...


Then, install the intake elbow and diverter coupling...


And lastly the intake airbox. Easy Peezy.



Next, installed the cold side charge piping that leads into the throttle body.


Once the throttle body coupling was attached, then I attached the intercooler coupling/elbow...


Make sure you don't forget the pipe stay.



And lastly, attach the vacuum lines to the vacuum block, and the block to the pipe.

 

[Toddasaurus]

Next I installed the passenger side strut tower brace, make sure you torque it down properly (20lb-ft)...


And then the front bumper/radiator top cover piece by putting in all the plastic rivets....




NOW - time to get ready to refill the coolant. First thing I needed to do was find the coolant bleeder hose. The FSM states that it's on the front, top of the engine block, underneath the wiring harness and under some insulation foam. I had to remove some of the wiring harness from the top of the block to make enough room to move it out of the way, take a look..

First, unplug and unclip the top of the engine wiring harness from the passenger side bank, as seen here...




Next, unbolt the plastic harness stay/guide/bracket from the top of the block so you can move it out of the way...



Now you can lift the stay/guide/bracket up, and remove the foam insulation block to reveal the bleeder hose...

There it is in all its glory...


Pop that little guy off to get ready to refill...


Don't forget the rags!

 

[Toddasaurus]

Now we are finally ready to refill coolant. I went ahead and just bought brand new OEM Hyundai coolant, along with some distilled water.




Using a 50/50 mixture I started filling.



After a while the radiator was full, but I still am not seeing any bubbles or overflow coming from the bleeder hose. That said, I need to squeeze some coolant hoses to push some of the air through. I'll finish that hopefully tonight. I also may got something to apply some positive pressure into the system....I don't know, we will see. Whatever it takes to get those air bubbles out.

Once I'm done with this, we'll start her up!!! Almost there!

 

[Beefer]

Now we are finally ready to refill coolant. I went ahead and just bought brand new OEM Hyundai coolant, along with some distilled water.
View attachment 23623
View attachment 23624


Using a 50/50 mixture I started filling.
View attachment 23625


After a while the radiator was full, but I still am not seeing any bubbles or overflow coming from the bleeder hose. That said, I need to squeeze some coolant hoses to push some of the air through. I'll finish that hopefully tonight. I also may got something to apply some positive pressure into the system....I don't know, we will see. Whatever it takes to get those air bubbles out.

Once I'm done with this, we'll start her up!!! Almost there!

WOW dude...all insane. At this point...you need to officially jack off on the trunk. Just do it. Show ownership...LOL.

 

[JeremyTD]

All modern reality series have a reveal at the end. I hope Todd's is that he's the technician at my local Genesis dealership.

 

[sethsquire]

All modern reality series have a reveal at the end. I hope Todd's is that he's the technician at my local Genesis dealership.

Man, if I could import Todd to be the service manager at my local dealership I would be happy to take my car there.

 

[danygenesis]

Ladies and gentlemen, take your seats and be ready.
Today is the GRAND FINALE of

I was at a loss....but....I FOUND MY WAY!