Dans Turbo Build

monsi · April 7, 2018, 11:17

I remember the vac and pcv lines being a bit of a nightmare....

I took a t off in the same place as shnazzle (after the butterfly of the throttle body) this feeds my ECU, recirculation valve and vacuum reservoir (for my exhaust valve).

Before the throttle body and after the charge cooler I have a takeoff that feeds to the wastegate actuator. This is where the boost solenoid would go.

This is what I have done with the pcv inspired by standard turbo engines. I added a check valve inline with the pcv valve (yes the valve is a one way valve, but is designed to avoid backfires entering the engine not continuous boost pressure and it's only plastic) the clean air vent and the back of the valve cover goes via a catch can to the air inlet before the turbo.

I have kept the evap system, but without it I guess you would remove the solenoid you have pictured block the manifold end and vent the fuel tank end via a filter (possibly some sort of fire arrester too?)

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dan944 · April 7, 2018, 11:20

My boost solenoid is here.

monsi · April 7, 2018, 11:37

I got my IAT sensor from efi-parts with the connector it cost about £25 with postage. They give you all the calibration data so it should be quite straightforward to setup.

I found fitting it into the silicone hose to be awkward, the fitting I ordered didn't allow the sensor to sit in the air flow so needed modifying...

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dan944 · April 7, 2018, 11:40

Nice, I got the boss from them. Getting it welded in to a 63mm pipe which will replace my maf pipe

monsi · April 7, 2018, 11:47

If you're using a metal joiner you could just drill it and bolt it through as long as you use some silicone or rubber washers to seal it.

I would be tempted to get a filter for the unused solenoid port something like

https://m.ebay.co.uk/itm/Solenoid-Valve-Pneumatic-Filter-Noise-Silencer-1-4-PT-Thread-Jsuaj/183147622000?epid=1138234611&hash=item2aa472ee70:g:snkAAOSwOh9auI3P

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dan944 · April 7, 2018, 11:58

I have some guys at work who can weld ally so will drop it in with them next week.

Unused solenoid pipe? Both of mine are used :/. One goes to the vac block and the other to the intake mani.

This is a night mare! The only part that's been difficult about the whole build is understanding these things!!

On a side note. I'm getting wastegate flutter (demented squirrel) albeit just a tiny bit. But should that be enough to register on my boost gauge?

dan944 · April 7, 2018, 12:05

Here's what I've got. Because a picture paints a thousand words.

monsi · April 7, 2018, 12:15

You boost solenoid will have three ports, the third port is on the opposite side to the one from the manifold. That is where the vacuum from the wastegate actuator is released.

Until you have an ECU capable of understanding boost you want the wastegate held open. I would expect that you would see some boost on the gauge, if the wastegate is operating.

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dan944 · April 7, 2018, 12:18

Ahh crap!!! Yes sorry. The boost solenoid does have a brass filter on it. I thought you meant the other little blue solenoid.

Sorry again. Also should've mentioned My wastegate is currently wired open. That's why I'm a little confused at the wastegate flutter and then also not seeing any boost on the gauge.

monsi · April 7, 2018, 12:31

I don't recommend you run it like that, the solenoid is supposed to allow fuel vapour from the charcoal canister into the engine when warm. The way you have it at the moment your boost gauge and ECU feed is isolated from the intake until the solenoid closes. So from your last post yes it is quite possible that you are making boost but the gauge won't show it. When the solenoid is closed you will either suck fumes from the fuel tank running rich or pressurise the fuel tank under boost!

You want the inlet manifold to connect directly to the boost gauge and ECU. You'll have to have a search for what to do with the fuel tank vent I think there were post's on spyderchat about it.

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shnazzle · April 7, 2018, 12:38

Dan, by solenoid do you mean the VSV? If so you need to not run your car this way

dan944 · April 7, 2018, 12:47

Exactly that. I'm changing it this afternoon.

Is this better?
Connected at the inlet Nani now not he fuel tank vent.

shnazzle · April 7, 2018, 12:57

That's better

dan944 · April 7, 2018, 13:01

Well thank you for this. Patience of saints the lot of you!!!

Thinks a better diagram of that needs to be bookmarked haha

monsi · April 7, 2018, 13:12

That's better your boost gauge and ECU will work properly now, but you can't connect the fuel tank vent to the inlet manifold.

The new ECU probably won't drive the vsv solenoid so you might as remove it, then as suggested here pipe the fuel tank vent to a filter under the car.

https://r.tapatalk.com/shareLink?url=http%3A%2F%2Fspyderchat%2Ecom%2Fforums%2Fshowthread%2Ephp%3Fp%3D913320&share_tid=58261&share_fid=3075&share_type=t&share_pid=913320

I haven't done this so do your research and make sure it's safe!

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dan944 · April 7, 2018, 13:28

So looking at it, it seems fairly simple and safe.

I'll sort that out today. Thanks again guys.

dan944 · April 7, 2018, 15:34

Sorted now. Getting as high as about 0.25 psi which is fine and it's seems to cope fine with that. Runs really well. Nice bit of demented squirrel. Can't wait to be able to connect the actuator rod to the wastegate flapper and get some actual boost going!!!

dan944 · April 8, 2018, 15:38

My car is faster? I did not expect this. Not yet at least.
I'm getting fractional boost. It's the nicest that my car has EVER been to drive, and fastest.

Is this going to blow it up? Am I fairly safe. It feels very good. Finally managed to bleed that damned coolant system. Takes me at least a week every time! I've really got the bug back, and hard!

Also, change of plan.
I was leaning towards a stripped out, road legal track car.

Now, I want heated seats, good quality music, an armrest.

shnazzle · April 8, 2018, 16:05

Boost is boost. Even 0.25psi is still more than stock. So you're probably at about 155 hp or so. Enough to notice. And the way it is delivered makes it more noticeable.
Just wait until it's mapped. It'll blow your socks off. And with the 630cc injectors, you're good to push 10.5psi all the way to the redline. Good times ahead!

1979scotte · April 8, 2018, 16:30

Quote from: shnazzle on April 8, 2018, 16:05
Boost is boost. Even 0.25psi is still more than stock. So you're probably at about 155 hp or so. Enough to notice. And the way it is delivered makes it more noticeable.
Just wait until it's mapped. It'll blow your socks off. And with the 630cc injectors, you're good to push 10.5psi all the way to the redline. Good times ahead!

Would you push 10.5 psi on Helen's?
I don't think I would have done it on mine. Not at max RPM.
What's the most boost a stock 1zz has survived?

dan944 · April 8, 2018, 16:32

I think that's lees? Isn't he running 12? But I think he said himself it's well ovedue blowing up.

Can I clarify though that it "shouldn't" blow up? It can deal with a tiny bit of boost?

dan944 · April 8, 2018, 16:33

And you're right. I shall not be wearing socks to Cambridge as they will be thoroughly blown off.
Glad I was persuaded out of the BOV.

That noise is addictive already.

1979scotte · April 8, 2018, 16:33

Quote from: dan944 on April 8, 2018, 16:32
I think that's lees? Isn't he running 12? But I think he said himself it's well ovedue blowing up.

Can I clarify though that it "shouldn't" blow up? It can deal with a tiny bit of boost?

Stock ECU will compensate fine for .25 psi.
Is Lee running 12? Brave.

dan944 · April 8, 2018, 16:35

That's ok then.

I'm sure he said that.

He said "running 12 psi is stupid" and think he said he doesn't know how it hasn't blown up.

Hat off to him. It's been running that for a while as well.

shnazzle · April 8, 2018, 16:56

Quote from: 1979scotte on April 8, 2018, 16:30
Quote from: shnazzle on April 8, 2018, 16:05
Boost is boost. Even 0.25psi is still more than stock. So you're probably at about 155 hp or so. Enough to notice. And the way it is delivered makes it more noticeable.
Just wait until it's mapped. It'll blow your socks off. And with the 630cc injectors, you're good to push 10.5psi all the way to the redline. Good times ahead!

Would you push 10.5 psi on Helen's?
I don't think I would have done it on mine. Not at max RPM.
What's the most boost a stock 1zz has survived?

Helen's is built to run 10.5, but it tails off at higher rpm.
The injectors (440cc) don't flow enough to be able to hold that boost up the rev range on a returnless fuel line.
Just think, on a returnless line, 43.5psi fuel pressure is reduced to 33psi at 10.5psi boost. So, that's a fair bit of fuel it ain't gettin.
Helen could opt for a return fuel rail and then boost can be maintained throughout the range, but she doesn't want that much power anyway. I would