Posted By: kj16v
kj16v Home build - 16VT hybrid turbo project - 14/03/2009 22:13
After a completely failed attempt to map some better fuel economy out of the engine. I thought sod it, I may as go for a bigger turbo and more power. Then a Garrett T04e compressor and housing turned up on Ebay and one thing lead to another...
Turbo
Standard turbo – but not for long
http://img17.imageshack.us/img17/8941/oemturbo.jpg
Dismantled turbo. From left to right: Nut, fan thingie, metal, some stuff, more metal, some more stuff, hot metal, fan-on-a-stick
http://img17.imageshack.us/img17/3482/dismantledturbov.jpg
CHRA
http://img17.imageshack.us/img17/6455/chra.jpg
T3 and T04 comps and housings side-by-side
http://img17.imageshack.us/img17/2020/compscompared.jpg
Comp and turbine back from being cleaned and balanced
http://img17.imageshack.us/img17/5579/cleanturbineandnewcomp.jpg
Built T3/T04e. Now with extra meaty chunks for a fuller flavour.
http://img5.imageshack.us/img5/7816/builtt04et3h.jpg
Prototype sequential turbo
http://img50.imageshack.us/img50/6950/sequentialturbo.jpg
While the spinney bits were being balanced, I took the manifold and elbow to work and shot-blasted them. Then I sprayed them up with some hi-temp paint I found in a cupboard. Man, I love shot-blasting. “Go on ’av that, unshiftable rust!”
http://img17.imageshack.us/img17/6/cleanmanifold.jpg
Turbo and manifold fitted
http://img15.imageshack.us/img15/8731/turbofitted.jpg
The actuator didn’t fit the new larger comp housing so I had to make a bracket to relocate it. A workmate very kindly machined this for me. It has a slot in the housing-end so I can adjust the actuator to fit between the water pipes.
http://img15.imageshack.us/img15/705/wastegatebracket.jpg
At this point I connected the turbo up to the stock i/c, and the actuator directly to the comp housing, and took the car out for a “shake down” ( I hate that phrase. Sounds so pretentious). At 0.3 bar base boost it felt about as fast as a stock 16VT. Very promising…
Intercooler
This Iveco intercooler has plastic outlet pipes that come out at 45*; really handy on one side but needed to come out straight on the other side. So I got my beloved angle grinder out, chopped off the pipe and used my soldering iron to tack it back on straight. As you can see it turned out pretty good.
http://img527.imageshack.us/img527/2131/intercoolermod2.jpg
I’ll just turn it round to check the other side and… Doh!
http://img527.imageshack.us/img527/9059/intercoolermod1.jpg
Unfortunately I forgot to take a photo of the finished end tank mod. I used JB Weld too fill the gaps and strengthen the tacked-on side to the pipe. On the other side I moulded the missing shape out of Quick Steel putty, with more Quick Steel around the base for strength. A few minutes later everything’s set as strong as steel and perfectly sealed. Seriously, if you’re into DIY car stuff you need JB Weld and Quick Steel in your life!!
Iveco i/c fits nicely with just some angle grinding to the metal airflow separator flap thingies.
http://img50.imageshack.us/img50/4365/intercooler3.jpg
Pipework just fits between rad and chassis with some careful negotiation.
http://img50.imageshack.us/img50/483/intercooler1.jpg
Other side connects to the stock inlet pipework. Also see cheeky air filter poking out.
http://img50.imageshack.us/img50/7617/intercooler2.jpg
I was going to leave the left-hand air duct off but I found out it holds up those rubber sheets above it. So I had to hack it up with the jigsaw. You can’t see it so it doesn’t matter how it looks. There also happened to be two convenient threaded bolt holes in the chassis to help.
http://img50.imageshack.us/img50/5773/intercoolerduct.jpg
Turbo to i/c goes behind rad and incorporates stock outlet hose. I wanted to re-use that because its silicone
http://img50.imageshack.us/img50/686/intercoolerpipework1.jpg
A tiny bit of angle grinding to the bumper and all done. Even the plastic undertray fits as normal.
http://img50.imageshack.us/img50/3893/intercoolerfitted.jpg
I wuv my angle gwinder!
http://img155.imageshack.us/img155/8400/powertoollove.jpg
Next on the agenda was to change the cam belt, and whip the balance shaft belt out and bin it – well, put carefully into a box. Those belts are expensive you know.
Everything done, I could finally go out on the road and start tuning. I made a short video of the tuning process, which I need to edit. I might post it up if it’s any good.
Petrol must have been cheap when Fiat mapped this because I ended up actually removing fuel most of the map. 16VT’s run stoopid rich on boost.
Tuning completed. The hybrid, combined with my mbc (cheers for the freebee, Simon! ) makes driving a lot more, er, fun. Now the car drives just the way I like a turbo to drive with that lairy “barely in control” feeling.
Got to get it dyno’d but by my calculations it should be making around 240bhp at a measly 0.8 bar. And before anyone pipes in with “Yeah well mine makes 250 with the standard turbo!” It’s not all about peak figures. It’s about how you get there too! The engine now makes ladles of torque all the way from 3000rpm and keeps pulling like train all the way to the rev limiter at 6800rpm, instead of dying a death at 5k.
So there we go. homebuilt t04e hybrid+Iveco Dailey intercooler+pipwork=Potential for approx 300bhp and all for a quarter of the price of a fancy-pants GTblahbla ball-bearing job!
Future plans? Probably:
High flow cat
Have a go at making a tubular manifold
Get bored and wind the boost up to 300bhp and…
…subsequent rebuild. Which will lead onto my…
…Super Secret Project That Nobody Has Ever Done Before So Don’t Ask What It Is Because If I Tell Someone Will Do It First - project
-UPDATE-
21/03/09- Well I bowed to (not much) pressure and wound up the boost to a more manly 1bar, along with a bit more mapping. Didn't need much but I smoothed out the AFR a bit so it stays a steady 12.5 up to the redline.
25/03/09- Burned my map on to an eprom (chip) at work today, so no more ecu lying in the footwell! Also ordered my own programmer to let me burn chips at home for this and other projects on the go.
Well, removed all the tuning gear from the engine bay and ecu is back where it should be. Job done?? C'mon we all know projects never end!
Well this talk on other threads of aiming for 300+ has got me wanting some of that. So next I'm thinking of building that 3" exhaust, and maybe having a go at a tubular manifold. Althought I really didn't want spead all my money and time on more car projects this year. Since that's all I've been doing for the last seven years (ah my first project, that good ol' trusty-rusty Nova)!
I want to get this dyno'd at Torque of the Devil, in Uxbridge. If anybody wants to join me, let me know on the comments thread.
Turbo
Standard turbo – but not for long
http://img17.imageshack.us/img17/8941/oemturbo.jpg
Dismantled turbo. From left to right: Nut, fan thingie, metal, some stuff, more metal, some more stuff, hot metal, fan-on-a-stick
http://img17.imageshack.us/img17/3482/dismantledturbov.jpg
CHRA
http://img17.imageshack.us/img17/6455/chra.jpg
T3 and T04 comps and housings side-by-side
http://img17.imageshack.us/img17/2020/compscompared.jpg
Comp and turbine back from being cleaned and balanced
http://img17.imageshack.us/img17/5579/cleanturbineandnewcomp.jpg
Built T3/T04e. Now with extra meaty chunks for a fuller flavour.
http://img5.imageshack.us/img5/7816/builtt04et3h.jpg
Prototype sequential turbo
http://img50.imageshack.us/img50/6950/sequentialturbo.jpg
While the spinney bits were being balanced, I took the manifold and elbow to work and shot-blasted them. Then I sprayed them up with some hi-temp paint I found in a cupboard. Man, I love shot-blasting. “Go on ’av that, unshiftable rust!”
http://img17.imageshack.us/img17/6/cleanmanifold.jpg
Turbo and manifold fitted
http://img15.imageshack.us/img15/8731/turbofitted.jpg
The actuator didn’t fit the new larger comp housing so I had to make a bracket to relocate it. A workmate very kindly machined this for me. It has a slot in the housing-end so I can adjust the actuator to fit between the water pipes.
http://img15.imageshack.us/img15/705/wastegatebracket.jpg
At this point I connected the turbo up to the stock i/c, and the actuator directly to the comp housing, and took the car out for a “shake down” ( I hate that phrase. Sounds so pretentious). At 0.3 bar base boost it felt about as fast as a stock 16VT. Very promising…
Intercooler
This Iveco intercooler has plastic outlet pipes that come out at 45*; really handy on one side but needed to come out straight on the other side. So I got my beloved angle grinder out, chopped off the pipe and used my soldering iron to tack it back on straight. As you can see it turned out pretty good.
http://img527.imageshack.us/img527/2131/intercoolermod2.jpg
I’ll just turn it round to check the other side and… Doh!
http://img527.imageshack.us/img527/9059/intercoolermod1.jpg
Unfortunately I forgot to take a photo of the finished end tank mod. I used JB Weld too fill the gaps and strengthen the tacked-on side to the pipe. On the other side I moulded the missing shape out of Quick Steel putty, with more Quick Steel around the base for strength. A few minutes later everything’s set as strong as steel and perfectly sealed. Seriously, if you’re into DIY car stuff you need JB Weld and Quick Steel in your life!!
Iveco i/c fits nicely with just some angle grinding to the metal airflow separator flap thingies.
http://img50.imageshack.us/img50/4365/intercooler3.jpg
Pipework just fits between rad and chassis with some careful negotiation.
http://img50.imageshack.us/img50/483/intercooler1.jpg
Other side connects to the stock inlet pipework. Also see cheeky air filter poking out.
http://img50.imageshack.us/img50/7617/intercooler2.jpg
I was going to leave the left-hand air duct off but I found out it holds up those rubber sheets above it. So I had to hack it up with the jigsaw. You can’t see it so it doesn’t matter how it looks. There also happened to be two convenient threaded bolt holes in the chassis to help.
http://img50.imageshack.us/img50/5773/intercoolerduct.jpg
Turbo to i/c goes behind rad and incorporates stock outlet hose. I wanted to re-use that because its silicone
http://img50.imageshack.us/img50/686/intercoolerpipework1.jpg
A tiny bit of angle grinding to the bumper and all done. Even the plastic undertray fits as normal.
http://img50.imageshack.us/img50/3893/intercoolerfitted.jpg
I wuv my angle gwinder!
http://img155.imageshack.us/img155/8400/powertoollove.jpg
Next on the agenda was to change the cam belt, and whip the balance shaft belt out and bin it – well, put carefully into a box. Those belts are expensive you know.
Everything done, I could finally go out on the road and start tuning. I made a short video of the tuning process, which I need to edit. I might post it up if it’s any good.
Petrol must have been cheap when Fiat mapped this because I ended up actually removing fuel most of the map. 16VT’s run stoopid rich on boost.
Tuning completed. The hybrid, combined with my mbc (cheers for the freebee, Simon! ) makes driving a lot more, er, fun. Now the car drives just the way I like a turbo to drive with that lairy “barely in control” feeling.
Got to get it dyno’d but by my calculations it should be making around 240bhp at a measly 0.8 bar. And before anyone pipes in with “Yeah well mine makes 250 with the standard turbo!” It’s not all about peak figures. It’s about how you get there too! The engine now makes ladles of torque all the way from 3000rpm and keeps pulling like train all the way to the rev limiter at 6800rpm, instead of dying a death at 5k.
So there we go. homebuilt t04e hybrid+Iveco Dailey intercooler+pipwork=Potential for approx 300bhp and all for a quarter of the price of a fancy-pants GTblahbla ball-bearing job!
Future plans? Probably:
High flow cat
Have a go at making a tubular manifold
Get bored and wind the boost up to 300bhp and…
…subsequent rebuild. Which will lead onto my…
…Super Secret Project That Nobody Has Ever Done Before So Don’t Ask What It Is Because If I Tell Someone Will Do It First - project
-UPDATE-
21/03/09- Well I bowed to (not much) pressure and wound up the boost to a more manly 1bar, along with a bit more mapping. Didn't need much but I smoothed out the AFR a bit so it stays a steady 12.5 up to the redline.
25/03/09- Burned my map on to an eprom (chip) at work today, so no more ecu lying in the footwell! Also ordered my own programmer to let me burn chips at home for this and other projects on the go.
Well, removed all the tuning gear from the engine bay and ecu is back where it should be. Job done?? C'mon we all know projects never end!
Well this talk on other threads of aiming for 300+ has got me wanting some of that. So next I'm thinking of building that 3" exhaust, and maybe having a go at a tubular manifold. Althought I really didn't want spead all my money and time on more car projects this year. Since that's all I've been doing for the last seven years (ah my first project, that good ol' trusty-rusty Nova)!
I want to get this dyno'd at Torque of the Devil, in Uxbridge. If anybody wants to join me, let me know on the comments thread.