Gary's Track Day/Fast Road Weekend Car 1zz Turbo.. Now Built 2zz Turbo with E153

[Gaz2405]

Had a couple of hours mapping the car this afternoon, low end stuff and mid range.

Had a play about afterwards, I'm going to need to add an external waste gate to my manifold and the internal gate on the Holset is struggling like mad even though I've ported the crap out of it.

I'll order the bit and get it welded up at work, thinking of just doing what the Honda boys do and just come off one manifold branch either cylinder 1 or 4, rather than trying to pillar drill into the center.

Never the less I managed to use by right foot as the boost controller, how does 18psi at 50% Throttle sound!

I've flattened the VVT Map to a flat 10* at the moment until I've got the boost under control and I've got lift turned off, turbo isn't as responsive as the TD04, but I've also not got VVT optimized or going WOT yet.


However, I can confirm that 18psi from this truck turbo at 50-60% WOT is on another level.

[Gaz2405]

Another few hours on the road today after a big garage clear out.

This thing is an absolute animal, tucked away now for winter. I'm spinning wheels in 3rd and 4th.

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I'll sort the external wastegate and re-do the exhaust over winter for a more permanent solution now I know we're cooking on gas.

 

[Gaz2405]

Wastegate and flanges arrived.

Took it into work today and got one of yh fabricators to weld it on. (Much easier than faffy about at home)

It's not in the ideal position to catch flow, but it should work fine and works in my engine bay

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[Gaz2405]

Out tonight for a few test runs, 450mm 38mm screamer pipe fitted.

No massive boost spike like everyone thought would happen.

Small amount of boost creep, but nothing in too worried about.

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19psi on the HX32 is very nice. 😁

[Gaz2405]

We had reasonably dry roads this morning, so I went out for some testing and mapping.

I'd ported my external waste gate a little more, as I'd had it welded internally and externally, so there was still a bead of weld around the inside to work on.

It is an absolute animal, I need to play with the second cam and maybe bring it in a little earlier and optimise the VVt timing.

I'll let the below screen shot do the talking.

18.5psi peak boost pressure tailing off to 14.5psi at 7.7k.

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Very pleased with it.

Next time out I'll get the GoPro out and get some runs filmed.

[Gaz2405]

Much more palatable on dry roads.

[thetyrant]

Rapid

[Gaz2405]

Rapid

This is just wastegate pressure too, can't wait to turn the boost up with the controller!

[Alex Knight]

Much more palatable on dry roads.

Properly quick that. Nice one.

[KRAMSNEHPETS]

Can you give me a list of stuff that you have done for your 2ZZ turbo build. Bought one a couple of years ago that is just sitting outside looking very sorry for itself. Issue with it is , excess crank pressure , appears that i might have had issues with cracking the oil control rings. Thinking of doing a build useing a spare engine that I have. Thinking darton sleeves with low comp pistons etc

[Gaz2405]

Can you give me a list of stuff that you have done for your 2ZZ turbo build. Bought one a couple of years ago that is just sitting outside looking very sorry for itself. Issue with it is , excess crank pressure , appears that i might have had issues with cracking the oil control rings. Thinking of doing a build useing a spare engine that I have. Thinking darton sleeves with low comp pistons etc

I'll try might miss a few things.

Engine

8.8:1 Mahle Pistons
MWR Rods
MWR valve Springs
Seven Motorsport Stage 2 Cams
ARP Bolts
Elise Parts Sump

Holset HX32 Turbo
3" Exhaust
600hp+ rated charge cooler

ID1050x injectors
Radium return fuel rail
340l fuel pump

EMU Black ECU

If you do go sleeved, I've got some brand-new wiseco 8.8:1 pistons that are 82.5mm.

[KRAMSNEHPETS]

thanks for the info

[Gaz2405]

New wideband sensor in today, old one had a hard time.

Also just about got cold start tune dialled and started working on the idle tune.

But I'll have to wait until it's cold again....to find out.

Settled with idle at 950rpm once warm.

[Gaz2405]

So I've been chasing what I thought was wheel hop on the NSR for sometime now.

Re-bushed the whole rear end swapped cool overs over. Nothing.

Was the LSD on the way out?

Yesterday I pulled the rear engine mount above the gearbox, as it's.most likely the original one on around 100k.

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Once it was out I figured I'd fill it with tiger seal to check before buying an uprated one.

Test drive tonight and low and behold it's more or less gone.

Success!

Also chased down an annoying rattle/vibration I'd had for a while, I was certain it was exhaust related. I managed to get pulled over whilst it was presenting itself.

Head in the engine bay, touching everything that wasn't hit to try and find it, no joy.

Sat with my arms on the rear bumper support and I could feel it....it's got to be near the rear.

Found it! Rear crash bar (I'd only put two nuts back in to hold it! Easy fix!

Whilst out tonight and getting the fuelling sorted better I passed an MX5 going up a long dual carriageway pull.

I'd pulled into the next lay-by as I was checking over the log.

He pulled up alongside, apparently I'm spitting 1ft long flames out of the dump pipe at full chat.

So two things I need to sort.

1.Some external drive bys or gopro on the rear bumper.

2. Get the dump plumbed into the exhaust.

Next step is uprated poly engine mount in the short term l.

[Nvy]

I want a gr yaris so bad but you are kinda inspiring me to get goin with my build and forget about another car for the time being. Great work and nice progress! I am happy that we are with you on your journey chasing big numbers.

[Alex Knight]

I kept on cooking the OS engine mount on track. I got through 3 used ones and 2 new ones.

In the end, I replaced all 4 with new OEM mounts. No issues since.

They play a bigger role than we all may think.

[Gaz2405]

I kept on cooking the OS engine mount on track. I got through 3 used ones and 2 new ones.

In the end, I replaced all 4 with new OEM mounts. No issues since.

They play a bigger role than we all may think.

Yeah seems that's the way.

[Gaz2405]

So I've been chasing my tail on this bloody cold start idle issue, thinking I've got it sorted then not blah blah.

After trying again tonight and seeing in the log that the IACV was getting duty and power, but still wouldn't hold an idle within 2% throttle.

Going back through my old logs and old maps. ( That's did idle and cold start) what have I done, what have I changed?
 Absolutely nothing, this thing should idle.

So I'm pinning my hopes in going back to basics.

Now this engine, with this throttle body and IACV never liked to idle before.

So I'm going to swap out the whole throttle body with one that I know has a working IACV.

Fingers crossed!

Annoying thing is, it idle's great after 50°c. But then I always favour using the ignition tables for idle control when warm.

So a little tinkering this week required.

[Gaz2405]

Those little IACV always seize up inside. There is 2 screws that hold it in - they are 5 point security torx but a hack saw will turn them into flat blades. Even the new throttle body, if I were you I would strip down the IAT coil block and the top cover, then spin it around drowned in WD40. They collect water and rust builds up on them.

I was giving the one on my mates Ignis turbo the same treatment 2 weeks ago, his would idle high, then not idle at all etc, I bet I've done over 20 of them. All the same design, think its a Denso thing.

I know, I'm kicking myself for not looking at it before I put it back in.

I even said to myself, "nah it should be fine".

It can only be that that's stopping it from idling from cold, I know the settings I have work in the map both on my car and another 2zx turbo for cold idle.

I need to upgrade the breather system/catch can anyway, so may as well have it to pieces all at the same time.

[Gaz2405]

Pulled the throttle body tonight, IACV crusted up. Soaked in WD40, free'd up.

Going to let it soak overnight then put back in tomorrow.

[shnazzle]

Pulled the throttle body tonight, IACV crusted up. Soaked in WD40, free'd up.

Going to let it soak overnight then put back in tomorrow.

Remember to lube it up again or you'll be back at square 1 soon. Been there. Done that 

[Gaz2405]

Remember to lube it up again or you'll be back at square 1 soon. Been there. Done that

Aye just pulled it and dried off, relubed and back in and together now.

Actually not that bad of a job.

If this fix works I'll order a new IACV just so I know it's a new one in there.

[Gaz2405]

Test ........in the IACV.

Started on the 1st turn and idled perfect.

What a bellend!

Lessons for us all, start with the basics!

Sorted now at least.

[Gaz2405]

I'm a bit perplexed on the ECU Master EMU idle settings for these Denso return springless pwm things... there are settings for frequency in hz etc, "3 wire PWM no spring", etc.

The one on my mates Ignis Turbo was setup by some "proper tuning place", but the coil block was unscrewed and the valve all seized up. It never idled consistently.

I've got it actually working, and it mostly hits its target idle pretty quickly, and catches before it stalls etc. But I just fudged about with stuff I don't know about... here is a picture of my settings:-



Would you share your setting to see if I'm barking up the right tree with the config?

Yeah no worries, just on my phone at the moment, but will fire up the laptop tomorrow

[Gaz2405]

I'm a bit perplexed on the ECU Master EMU idle settings for these Denso return springless pwm things... there are settings for frequency in hz etc, "3 wire PWM no spring", etc.

The one on my mates Ignis Turbo was setup by some "proper tuning place", but the coil block was unscrewed and the valve all seized up. It never idled consistently.

I've got it actually working, and it mostly hits its target idle pretty quickly, and catches before it stalls etc. But I just fudged about with stuff I don't know about... here is a picture of my settings:-



Would you share your setting to see if I'm barking up the right tree with the config?

Idle settings below Anon 👍

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