Kurt: Engine
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Throttle body Fuel Pressure Regulator mod


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turbo crank, std. juornals, polished, neutrally balanced (within 1/4 of 1gram)
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bored over
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block was tanked, magnafluxed, new freeze plugs
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Wiesco, arp fasteners, pressed pins
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no Silent Shafts, new timing components - water pump
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waiting for a car
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Arp head studs
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ACT HD clutch kit
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trans is original to the car
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1mm OS SS valves
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prefitting flywheel
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installing springs, these are stock
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Fel-Pro head gasket
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flywheel was removed then heated again and installed with locktite
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port TB top and bottom
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note:water to be eliminated from TB, going to plug the hole in the lower center
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so no debris can get in
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the plug will protrude slighty into the buldged area at the top right of center
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plug we used
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intake was ported
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plug installed
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well the exhaust pieces are off being ceramic coated and a few other parts were
removed to be powdercoated
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started it up briefly and pumped up the oil
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gauges being installed
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more CONCRAP!!
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Starion lenses
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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"
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the oil separator and vacuum tank were moved back where the abs canister used to be
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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
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still waiting on the coated parts.....
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carnage
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I found the TR intake (again)
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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
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same fittings as the truck, actually had to rod the truck cause only one fitting came in
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the orange stuff is called "firesleeve", the keep the water lines from getting too hot and to make them last longer
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not my choice for an oil drain but will work until he swaps it for the j-tube
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it's starting to look like a car again
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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
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that coating shop is going to get allot of business from me!
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Kurt has the mas at home, he had to assemble it
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this is my favorite part
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stock heat shields will fit with some persuasion
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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.
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turbo plumbed by flexible hoses
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tightening the header back on, all accessible from the top side
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the EGT probe is in the downpipe
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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
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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.