Kurt: Engine 

Click here: Throttle body Fuel Pressure Regulator mod


turbo crank, std. juornals, polished, neutrally balanced (within 1/4 of 1gram)

bored over

block was tanked, magnafluxed, new freeze plugs

Wiesco, arp fasteners, pressed pins

no Silent Shafts, new timing components - water pump

waiting for a car

Arp head studs

ACT HD clutch kit

trans is original to the car

1mm OS SS valves

prefitting flywheel

installing springs, these are stock

Fel-Pro head gasket

flywheel was removed then heated again and installed with locktite

port TB top and bottom

note:water to be eliminated from TB, going to plug the hole in the lower center

so no debris can get in

the plug will protrude slighty into the buldged area at the top right of center

plug we used

intake was ported

plug installed


well the exhaust pieces are off being ceramic coated and a few other parts were removed to be powdercoated

 

started it up briefly and pumped up the oil

gauges being installed

more CONCRAP!!

Starion lenses

 


We started the engine today for a few seconds just to pump up the lifters and do a second compression check, the results were the same 150-151psi in all cylinders

You may "mouse over" this picture below to see that happening

Had someone blowing into the MAS since nothing is connected while holding the oil feed for the turbo so it would dump back into the head.  The initial fire up shot a couple flames out from us testing the injectors and the timing then a poof of smoke from all the oil and assembly lube in the cylinders and then he ran out of breath so we tried one more time and the band started playing!  Wow, what a flow from that turbo feed line. 

  03-08-06


the continuing saga  G54B-K3   (Kurts 3rd G54B build-up)

and the secret word for today is.... "relocation"

the oil separator and vacuum tank were moved back where the abs canister used to be


 

 

Ubend for the inlet, one 45 pipe to connect the compressor outlet J-pipe to the stock i/c piping (slightly modded one part) at the radiator support

still waiting on the coated parts.....

carnage

I found the TR intake (again)


Spend much time under your car? 

grind the flashing off your valve cover, it makes a big improvement in appearance

and after the paint dried

also powdercoated the pusher fan, ignitor box and mas lid

replace the filters in your cruise actuator

some large diameter shrink wrap fixes these burned cables


okay, it's the last day, 3/25/6.  the mas is coming, the radiator needs filled some adjusting to the tps and isc and off the the BMV than back for the a/r and egt then it's off to Kurts house in Plainfield

same fittings as the truck, actually had to rod the truck cause only one fitting came in

the orange stuff is called "firesleeve", the keep the water lines from getting too hot and to make them last longer

not my choice for an oil drain but will work until he swaps it for the j-tube

it's starting to look like a car again

see, no clearance problems from using a dsm turbo with our header design, the c/s turbine housing would stick up about one inch higher

that coating shop is going to get allot of business from me!

Kurt has the mas at home, he had to assemble it

this is my favorite part

stock heat shields will fit with some persuasion


3/26/6 all the parts are in, the head was retorqued that next day after he took it home, the oil was changed today and so far he has driven just about 400 miles.  The header was removed and the mating flanges ported to match each other.  There was so much added flow and low end torque.... boost comes in around 1200 and full boost at 1800rpms and you can chirp the tires into 2nd gear at just 6psi boost.  The car has averaged 22mpg and that has been with a many high boosts upwards of 20psi.  Boost creep has been the only problem, today the wastegate flap and turbine housing was ported and that creep was cut back to about half was it was.  It was stopping around 9psi then creeping up to around 18-20psi depending on the rpms.  Now after that porting it stops about 13psi.  The problem is the exhaust is flowing so well the gases would rather go out the turbine wheel and not the wastegate so after the boost limit hits, there is a pause and it slowly climbs-this is called Boost Creep.  This only happens if you let the rpms go high by not shifting or just do it on purpose.  The problem is the wastegate flap was ported to allow it to open fully 90 degrees from the port but the wastegate actuators only will allow about 1/3 of that since their movement is so small, about 3/8" and it needs to be moving at least an inch.  We are going to make a triangular intermediate plate to attach the actuator arm to the wastegate flapper arm.  That will be the project for Tuesday.  The opened up hot side has been a HUGE inprovement.  You can put in hardpipes or a larger intercooler or a 1G mas or a different injector or a cam -well we have tried all those on other motors but this by FAR has surpassed all those combined, the cam in here is stock, the lifters are hydraulic, the intercooler and the pipes behind the header panel are stock as well are the injectors that have been cleaned.  Starting from the exhaust and going back to the air filter has resulted so far in more gains than going in the opposite direction.  We can only guess now the other additions will continue to show greater gains.  Most just ignore the exhaust manifold and say it's fine because they won't go the expense to make or buy a header.  You need to experience one; you'll change your mind.  See the header link for the porting we did on that.

turbo plumbed by flexible hoses

tightening the header back on, all accessible from the top side

the EGT probe is in the downpipe

two brackets were cut from the body to allow the air can lid holding the 1G mas to go all the way down and touch the bottom

3/29/6

The boost creep went mostly away after the porting and the tuesday linkage change we didn't do.  Today he put on a MBC and the creep is gone, it was partially the boost exciting the actuator and pushing it open causing the lag before the creep but when the MBC stopped that pressure from loading up the diaphram in the actuator it built boost even quicker so he set it up for 15psi ( the creep was stopping around 12psi if you just used the stock actuator without a MBC and just hooked it all up stock ) and ran that a few times then in the evening took it up for 20 a couple more times.  Still a few bars in the green.  We are going to put in a series of Hobb's type pressure activated solenoids to control some boost levels from inside the car and get ready for some water injection next.  The  shop here we got most all of the fuel parts for truck from that has the dyno moved last winter and their open house is Saturday and the dyno is going to be open so we are going to see where we are at hp wise.  It's a 4x4 shop and seeing a Japanese car come in...well we'll see.