B4Q 80-AEB TD04HL-15T; Loads of rewiring!

[ringbearer]

Powerflex?

[ChrisAudi80]

What did those poly bushings for the inner tie rod come from? Want to replace mine but it doesn't look like anyone makes any.

Oh, they were some PU parts locally made laying around my mechanic's shop. They were close, but had to be machined to be made to fit.

Not Powerflex.

I'm not 100% satisfied with them because the sleeve is not the same diameter as stock, but works for now.
It would be better to use the old steel sleeves and pour PU around them.

[ChrisAudi80]

Been a long time since updates and plenty of things have happened.

In June, spent a bunch on new EBC rotors and EBC Red Stuff pads all around. Sure makes a difference, but not major. Unless working the brakes hard. They bite harder when warmed up. Got the stock calipers painted red.

Also got some more bushings from AK MS. Front and rear ARB and snub mount.

The fuel tank has been redone. It's actually bolted to the chassis now and has a rollover valve on the vent! Redid the pump set up in the tank and relay wiring. Still not totally happy with it.

All rubber lines have been replaced with AN-6 PTFE hoses and I got a great deal on a Fuelab regulator and billet fuel rail from speedingG60.
All installed now with a 100psi fuel pressure sensor. I have also installed a post-turbo pressure sensor and put the EGT sensor in the same place to use as post-turbo temp sensor. Works great. In full boost, outlet temps can hit up to 180c, IM IAT shows 52c or so.

The stock PCV system has been completely eliminated and got the block breather adapter from IE that connects to an AN-10 push-on going to the catch can.

Coming up is the turbo swap. Bought a SAAB TD04HL-15T, no shaft play. Got a cast EM with T25 flange. Should be good for 300 crank. It'll run out of injector at 3 bar base pressure, but might squeeze by if going to 4 bar which corresponds to 727cc.

Learning more about tuning. The tune is getting better, IMO. No idea where I am on the Dunning-Kruger curve.

However, the clutch now slips. It has 50,000kms of abuse on it so I guess that is OK life span. Will get it redone when the turbo swap is being done.

[ChrisAudi80]

Clutch swap and turbo swap in progress. Did a bunch of work this past week.

The rebuilt clutch and pressure plate assembly arrived Friday late, so don't have any pictures of that now, but I do have some of the old clutch plate. As you can see, it was done and left a bunch of shit inside the bellhousing.

The TD04HL-15T is fitted on the EM. The stock oil feed line bolts up, but the hardline had to be shortened 70mm and rotated about 45 degrees.
Coolant feed was relatively easy too. Used a banjo fitting I had laying around for that. Connects right up to the stock hose. Oil and water return is up next week.
One of the AC lines to the dryer was in the way of the oil drain and way too close to the turbine and down pipe. That has been modded too.
You can see what it was like.

Replaced the valve cover gasket as it was leaking.

Pics

[ChrisAudi80]

Today was a big day.

Had the car towed to the exhaust shop. Down pipe was modded to the new turbo and wrapped it. Have a 2.5" V-bad at the bottom now.
Also had them make the compressor to IC pipe and the intake pipe. Plenty of pie cuts.
I will put some kind of air box around it. Eventually.

The shop is a bit rough and not all the welds are pretty, but it works.

Also, pictures.

[ringbearer]

Sweet! Love the pics, no OSHA out your way

[pilihp2]

Welding barefoot with no gloves. ho man. that's hilarious.

[DE80q]

Welding barefoot with no gloves. ho man. that's hilarious.

Hey wait... He has flip flops on!

[ChrisAudi80]

You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.

Anyway, the clutch needs needed a lot more bleeding. It is still hard to get it into gear. The AC system needs a charge.
Really looking forward to driving and tuning this.

If I got this right, the turbo should be good for 300 crank.

[ChrisAudi80]

Went for a long drive today. About 300km or so.

This thing is LOUD! First thought the stock 710n was done, but then went for a boost leak test. Should have done that sooner.
Found three leaks. Fixed that.

The stock DV was fine, but still lots of whooshy sound. Very noise, much wow. An open pod filter is quite noisy.

Will see if I can make a decent vid to post up. The tune is coming along nicely. Only have it up to 170kpa at this time.
It does need more throttle input now to make boost, but it is quite controllable with throttle.

Smiles for miles

[ChrisAudi80]

Tuning boost control.

Target 180kpa, spikes a little to 192kpa. Sure is a different car now...

Anyone have advise for working with the circled part? I have read the boost control guide many times.
I think I get it, but need a few pointers.

[ChrisAudi80]

A little test run...

https://youtu.be/loehvMo0miE

[PRY4SNO]

Seems pretty responsive for freeway driving, bet it feels nice.

Is that compressor stall on the lift off, or your BOV?

[ChrisAudi80]

Seems pretty responsive for freeway driving, bet it feels nice.

Is that compressor stall on the lift off, or your BOV?

You mean surge? No, I think that is induction noise and the STOCK DV blowing off.
This car has no MAF and an open pod filter.

I have a post-turbo MAP sensor hooked. It shows slight boost. Say IM MAP is around 86kpa, the post turbo shows 122kpa. Because of that,the DV opens slightly.

[mrdeye]

You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.

Yes!!! MTGA! Deregulate! Dude working like he’s building a model at the kitchen table. Cool project!

[ChrisAudi80]

You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.

Cool project!

[ChrisAudi80]

Still just running 180kpa. Starting to get the boost control dialed in, I think.
The turbo still needs about 0.8sec to hit boost target. Full spool at 3400, but can get 180kpa already at 2800 if I load it right, but it becomes like a dog then.

Have played with the timing a little bit. Managed to reduce load at 120kmh cruise from 83-85kpa to 72-75kpa. TPS did not really change. Maybe from 23 to 21%
More response and torque in most places.

Did a little compression test today.
cyl 1: 152+
cyl 2: 170
cyl 3: 160 something
cyl 4: 175

But that was cold and the pressure blew the tester off. I didn't use the screw in adapter.
Still need to check hot.

[ChrisAudi80]

Been working on boost control. So far, with the settings in the picture, I get the results seen in the other two.

This is a log from Sunday when I tried to keep up with a new Panamera. Yeah, right...

In unrelated news, the left front shock is bad again.

And found out the AK MS ball joint strut mounts had dislocated the ball joint out of the housing. There is a groove for retaining C clips, but there are none. Looked at the picture from when I got them. No C clips.
Odd. However, the ball joints pressed right back in. I bought and installed 034 Track Density strut mount bushings because I thought the ball joints were worn out. Nope.

[ChrisAudi80]

So, turns out I had to buy two new shocks. Great. Luckily not expensive.
Will see how the 034 track density strut mounts work out compared to the ball joints.

[ChrisAudi80]

Running out of injector...

Hitting 21ms PW and 89% max. I could increase the FP to 4.0bar, but then would have to run quite rich in the very low load areas.
Already sitting at 1.7ms @ 1000 rpm and 52kpa idle. I can see EGO struggling to keep lambda at 0.95.

[ChrisAudi80]

For a long time, the fuel tank gets quite hot in the afternoon. The pump was not so large that it should not heat the fuel so much.
Decided to have a closer look at the pump and wiring. Yeah... Not good. As you can see in the picture, the 12v supply wire was a disaster waiting to happen.
This pump and plug with wires is about 5-6 years old and had 60,000km on it.

Swapped out the old AEM 320lph pump to a Walbro 342 255lph and made new wiring (2.5mm wires). Forgot to take a picture of that of course. The in-tank plumbing is all AN-6 with PTFE hose now. The AN-6 5/16" ID hose fits perfect on the pump.

Before this, I changed some small things in the trunk. Added a check valve on the fuel feed line so I don't have E85 spraying everywhere when I need to open the tank for the umpteenth time. Also added a ball valve so I can take pressure off the line if needed or to take a sample. That flex sensor is doing FA right now. Quite sure it is a fake, but will try to send the signal through a frequency to voltage converter I am slowly making.

In the engine bay, redid the crank case breather hose with AN-10 hose and fittings. Already had the IE block adapter.
The old hose was sweating oil because it was for coolant only.

Hopefully will be able to make a new VEMS to Motronic adapter harness and subharness for the fuel pressure sensor, coolant pressure sensor, wideband and EGT during Christmas.

[ChrisAudi80]

Have had a few educational days.

Changing the in-tank hose from pump to bulkhead to PTFE from nitrided rubber and using PTFE line from IM to FPR was a bad idea with the Walbro.
For some reason, it created a resonance at 2750-2900rpm. It suddenly wanted 10% more fuel in that small band, but only in vacuum.
WTF. My VE table was suddenly all wrong. Everywhere.

So, last night, changed it back to rubber hose and silicone hose from original nipple to FPR. It is much longer than the AN-3 PTFE line, but it fixed the issue.
The light came on after watching this VERY educational video(s) from Injector Dynamics seminar at PRI2012.

https://youtu.be/4QF5BmQtXZA

This dude knows his stuff and can explain it very clearly.

BTW, why do I have over 80k views but few comments?

[audifreakjim]

I'm a lurker Paul Yaw is awesome, follow him on FB too. He has some pretty epic rants from time to time. He helped me diagnose my hot start problem that I swore was fuel related, but turned out being heat soak of the ignition coils.

[PRY4SNO]

Glad to see you found a solution.

I follow along, but try to only post when I have something to add so as to not clutter up your thread. Usually I'm stumped, or learning something new!

[ChrisAudi80]

I'm a lurker Paul Yaw is awesome, follow him on FB too. He has some pretty epic rants from time to time. He helped me diagnose my hot start problem that I swore was fuel related, but turned out being heat soak of the ignition coils.

Lurking is life. I get it.

Yeah, Paul is quite passionate. Hehe.
Cool that you got him to help you. Hope your Comet is still running well. Haven't seen any updates for a while.
Or maybe I missed them.