B4Q 80-AEB TD04HL-15T->16T 630-> 1150cc

[ChrisAudi80]

Wow, it's been a long time since an update. The COVID thing gave me lots of time to work on stuff.

The back pressure sensor and EGT sensor in front of the turbine are finally in. Haven't hooked up the new EGT yet because I want to integrate it into the current sub-harness. The BP is working now. And yes, the turbine is restrictive. Have a EMAP/IMAP ratio of 2.5:1. No bueno.

Also installed the water injection stuff, but with less success. Found I cracked the top of the pump and some funny things happen PWMing the DO solenoid with VEMS. Solenoid is connected to EC36-34. The nozzle holder is in, but I'm not happy with how I mounted the hose and solenoid.

Oh and managed to damage the compressor wheel with my dumb ass.

Pictures.

[ChrisAudi80]

The next part is to focus on the WI system and get it running the way it should.
It will be interesting to see what effect, if any, pre turbo injection will have on EMAP, EGT, compressor outlet temp and IMAP.

In unrelated news, I have built an injector flow test rig. All custom made. It can test 8 injectors at the same time and can simulate engine running.
It uses a Link Extreme ECU.
Been working on it for some time. The glass tubes are 1600cc each so plenty to test large injectors.

[PRY4SNO]

That's a pretty nifty injection fitting you've fabbed up. Can't wait for more results with the w/m injection project.

[ChrisAudi80]

Hey all, time for another update.

Got my injector test rig running well and have made my first batch of flow and offset matched injectors. Bosch EV14 modded to 1170cc. I have 3 sets of 4 1170cc injectors. Looks like two sets will be shipped soon.
The leftover injectors are now in the AEB. Piece of cake to tune. It really helps to have the right voltage offsets.

The 15T turbo was worn out. CHRA is done and a good deal on a TD04HL-16T from a Volvo came up on FB marketplace. Swapped that in after a bit of clean up and fiddling around. Bolts right in to the old hotside. Got a new turbo to IC pipe welded up yesterday and it should flow way better than the old monstrosity.

Not managed to get the water injection running properly yet. Want to get a diode for the water solenoid as I think there is too much flyback even for a ignition output.

Tomorrow will go for a test run and logging/tuning session.
Pics coming soon.

[ChrisAudi80]

Some pictures.

Next step is to replace control arm bushings (right side torn) and engine bushings. Back to stock. And put the AK Motorsport ball joint top mounts back. Sick of replacing 034 top mounts. Got a replacement and put C clips in to hold the ball joints.

The K type in the outlet shows 170c at WOT @ 210kpa, top of 4th. I love data.

The engine with new turbo and injectors is dialed in fairly well now. Max injector DC is at 52%. Will try out injector end angle tuning next to test to see how it works. Along with the bushings I will also put in a diode to control flyback from the water injection solenoid. It might have killed a channel without it.

Tech tip: If you ever use a TD04HL with stock oil drain, an AN-12 PTFE hose slips right on, just tight enough. Also, the stock Volvo turbo has a Compressor Bypass Valve. The diaphragm might be K, but the seal ring is not. Got a block off plate from Mamba and now it doesn't leak! Yay.
Turbo holds 204kpa to 7000.

Whenever this COvid crap is over, there will probably be a dyno day with the local car club.