7AFE Turbo kit install by DCW, To one of our good known members celica :) Options

[doGGy]

Well guy and girls - i can proudly present another project witch i will try to document / write-up / expain to a smallest details as posible. The project is install of a Turbo kit to a Martin (malpaso) 96' ST celica.

Works begin tomorow - so i will try to write up every single day of work i will be spending on his car, all the jobs what was done, and what things are installed and WHY they are installed + how they work and etc. Hoping to make this write up to be usefull to a people who will be doing the same thing later, and for the people to understand better how things work and etc.

Keep and eye on this topic - cuz it will have lots of info and pics in the long run

As for now - Martin celica is securly standing in my yeard - and Martin is traveling back home with the bus (20h drive oh man.... ), so lets hope the owner will give his response in this topic later

Romas

[Kadett]

20H drive?!?! Damnz.... then.. the car is now left with the European genius
Really interested in this Topic and already bookmarked it in Firefox.

[doGGy]

European genius

LMAO - you know what came to my head reading these words (European genius ) - This:


Lol sorry just had to post it Im not a genius at all, im just a guy whos extremly (even stupidly) intrested in celicas

Thanks Kadett

[OOBE]

Subscribing...

[trd94]

i will be keeping a eye on this, i want to see a pro at work!

[Drew-887]

I can't wait to see this project finished. Maybe it will give me some ideas.

[Fate]

watching this thread to the fullest, please don't leave us hangin' once you begin.

[snapshotgt]

Martin, you have a nice, clean Celica -- i'm sure you're looking forward to this new-found power.

Good luck with the waiting...it is the worst part -- trust me, i know.

[presure2]

looking forward to your results romas!

[TomPoz]

I had a pleasure to meet Martin on his way to Romas. Car looks (and sounds!) like GT, at least. With "T" in its engine this will be a killer. Hopefully I will be able to see the car (maybe test drive?). Also, we might be able to give it a test run vs. 3SGTE.

Romas, don't forget to label it with DCW sticker. Everybody is asking me what they are about on my GT4. The answer is: this is the label of the most exclusive tuning workshop that Celica could be worked on in.

This post has been edited by TomPoz: Jan 10, 2007 - 7:14 AM

[WH95TE]

In for later.

[malpaso]

Back from death at last . Fell a sleep for many hrs when I got back home (details about my journey here ). Thanks for nice topic Romas, I'll keep my eye on it for sure

[doGGy]

Well - tomorow is the day when everything starts. First thing from early morning - Martin's Celica will take a trip of 60miles to get the Leak Down test done and to see what we have inside of his 7A. Engine from outside seem a bit too oil'y, but this might be cuz our little friend removed the Valve cover for painting and after removal it leaks - so valve cover gaskets are already ordered

If leak down test will show good results - saturday works will be started.. So lets all pray for his engine - cuz if no good news - i will have to source the long block of the 7A for a quick change up - cuz i do have the perfect 7A head with only 4K km on it...

So tomorow first info will be posted, and first pics will come up

[shin]

def looking forward to it.

[Bitter]

Well - tomorow is the day when everything starts. First thing from early morning - Martin's Celica will take a trip of 60miles to get the Leak Down test done and to see what we have inside of his 7A. Engine from outside seem a bit too oil'y, but this might be cuz our little friend removed the Valve cover for painting and after removal it leaks - so valve cover gaskets are already ordered

If leak down test will show good results - saturday works will be started.. So lets all pray for his engine - cuz if no good news - i will have to source the long block of the 7A for a quick change up - cuz i do have the perfect 7A head with only 4K km on it...

So tomorow first info will be posted, and first pics will come up

bigport G head swap ftw! a little out of the budget perhaps.

[snapshotgt]

With your setup in mind, how much hp are you going to try to go for?

[doGGy]

Just got back from GroundZero (company who did Leakdown and company who will do a Dyno tune) with some good news Martin already knows the good news, cuz i Sms'ed him on the road back.

Well the leak down showed some good results, i was expecting worse, cuz Martin was talling me what previous owner had put some Oversize pistons and etc etc for the better performance But it seems like the engine was not opened and still in a original shape, so it might be what the prev owner was just braging about this to "better" sell the car




So the leak down showed what on the 1 cilinder we have 90% of life still left, on the second 80% on the third 85 and on the forth 80. So it seems like the engine is still in pritty good shape as it has done about 80K miles, and its almost normal wear for a 11 years old engine

So we wount need to find a new long block This will let the Martin to save up some penies

While i was walking around in the GZ garage, i saw one thing what couth my eye:





i thought Hmmm, maybe we should swap this one instead of turboing the poor 7A? I bet it would be fun to drive celi with this engine

Some one can guess from what car this engine came all i can say what it has 860Whp

[6strngs]

subscribing...

[doGGy]

oooooook 4 hours of work - and my old ST turbo kit got removed finally from the engine. Cleaned everything out, diched few things out - cuz some things will need to be made from new, already ordered all the new flanges for the inlet / outlet for the oil to turbine, for a downpipe and etc. Here are few pics of the stuff what will be put on the 7A to squizze some power

Whole kit placed together on the ground, still there are no silicone houses for the vacums, lots of small stuff is still not in the pics:



As for now - i will try to describe all the stuff what is included in thi Turbo kit and what they do and how they work:

1.In this setup im using Rising rate FPR (fuel pressure regulator) from Mallory, it is needed to inclease fuels pressure over the stock cuz you will be using bigger injectors and Turbo engine need more fuel:



How it works: WEB site how it works and what are the types of them >>>

2. Blow Off valve from Greddy, its a Type-S model. It is needed to reliese the pressure in the intercooler pipes when you let the gas pedal off and trottle buterfly is closed.



How it works and what are the types of them: Blow Off Valve >>>

3. Gauges im using in this setup are from SLM manufacture. Im gonna be using Boost pressure / Oil Pressure / Oil temp / and EGT (exhaust gas temp gauge).



I think most of us know how they work and why they needed

4. Exhaust manifold what i will be using was custom build by me Its hard to find one for the 7A block, so as we all know some people managed to use Honda B16 manifold with 7A exhaust manifold flange welded on it - so this is i think most cheap and best solution.



5. Turbine what will be used is from Garett, its a T3 turbine witch was build specialy for the my 7A setup.



Here is some info on the Turbine / Manifold and all related stuff: Info >>>

6. For the managment of the Fuel / Ignition - im gonna be using Greddy Emanage. This is one of the best PiggyBack Ecu's IMHO for the priece (now it is availible to get Emanage Ultimate witch is better, but a bit too pricey...). The major thing using this Emanage over all other piggybacks - si what you can correct Injectors setings (When using bigger injectors) doing this at the same time you will Fool yuor MAP sensor and it wound be seeing boost.



7. Injectors are from Ford Probe Turbo / Mazda MX5 Turbo - 330cc. 330cc is good enouth for about 220hp. If you are aiming for more - go with somthing bigger. The main thing to know is what 7A uses TOP FEED injectors what are HIGH impedance (16 ohm).



8. Boost controller is from Greddy, it is Profec B II (actually i was impressed with the easy to use Greddy Profec B - and i upgraded to Profec B II witch IMHO isnt worth the money cuz it is a bit too dificult to set it up...) Ofcorse if you want cheaper option - you can just go with a simple manual boost controler. But i chosed Electronic one to have 2 setings (hi Boost and Low Boost) witch can be set from drivers position and what there was options to avoid Boost spikes.



9. Intercooler is from Mitsubishi Starion, i rewelded inled and outlet on it, what it was easyer to make the piping on the Celica setup. Intercooler can be used from all the different cars, or universal use. All you wount need before buing intercooler - is to know what piping you will use, way too big piping diameter will give you a bit bigger lag (witch imho isnt so noticible...)



10. If you gonna be placing gauges on your setup (like Oil temp / oil pressure) you will definantly need some sort of distributor for the gauge sender to place in. In my case - i made my own simply taking aluminium piece and drilling one hole straight on it and one hle from top. In the pic you will see how i made it One thing needs to be noted if you gonna go with somthing like i did - you have to mount it on the Chasis of the car - and not on the engine - cuz engine vibrates, and it might be a change what you will be loosing the bolts and etc...



11. Downpipe is obviusly custom piece - witch can be made at any exhaust shop. all you would need is flanges. In my case - i went with totaly custom exhaust + i made my self a down pipe too. Be sure to heatwrap the downpipe - cuz its the main source of heat (along with the header) so it is good to wrap it to avoid some heat in the engine bay.



12. Catch can is from Greddy.



Why it is needed? It collects the oil witch goes from valve cover breather to the intake manifold - instead of letting the oil straight to the intake - you connect the catch can between the breather and valve cover, so this way all the oil sits in the can. You get the cleaner A/F mixture.

For today whats all I will be taking pics of every step while installing all the stuff. If some one can add or correct me (i know i will need to be corected ) please add - im trying to make this tread as usefull as posible!

Manny - i know you know 5x times more then i do - feel free to correct / add info on all the stuff!!! THANK YOU

[GTSOwner]

2. Blow Off valve from Greddy, its a Type-S model. It is needed to reliese the pressure in the intercooler pipes when you let the gas pedal off and trottle buterfly is closed.

Sweetest sounding BOV, ever. Had it in the DSM... *drool*

Malpaso, I hope the wait won't be too painful.

[6strngs]

12. Catch can is from Greddy.

[img]

Why it is needed? It collects the oil witch goes from valve cover breather to the intake manifold - instead of letting the oil straight to the intake - you connect the catch can between the breather and valve cover, so this way all the oil sits in the can. You get the cleaner A/F mixture.

sorry, a little off-topic, but is oil supposed to come out of the valve cover breather? it was doing it on mine and I thought something was wrong.

[doGGy]

12. Catch can is from Greddy.

[img]

Why it is needed? It collects the oil witch goes from valve cover breather to the intake manifold - instead of letting the oil straight to the intake - you connect the catch can between the breather and valve cover, so this way all the oil sits in the can. You get the cleaner A/F mixture.

sorry, a little off-topic, but is oil supposed to come out of the valve cover breather? it was doing it on mine and I thought something was wrong.

Its not what its pure oil - its a mixture of a oil and water (i dont know how this thing is called in english ) this consentrate always gets in the valve cover and its supose to go to the intake manifold, and get burn along with your air/fuel mixture in the cilinders. Under high load, if your engine has some wear, its ussualy some some pressure goes through your piston rings and gets into oilpan, and from there - the pressure lifts up some oil through the oilpan breather canal to the valve cover. So if you are on the boost - the chance of letting some pressure to the oilpan is x2.

Same goes on the naturaly aspirated engine - on high rpms you get the same thing.

[Alan]

Is a boost retarder included in Martins kit, he is gonna need one !

[trd94]

so are you wiring in the emanage your self or having a shop do it as i have one i want to put in my 7afte but i dont want to messup anything

[doGGy]

Is a boost retarder included in Martins kit, he is gonna need one !

Boost retarder? If you mean Boost controller - then yes, its a Greddy Profec BII.

As for Emanae - im wiring it my self, so i can post wiring diagram.

[Alan]

Is a boost retarder included in Martins kit, he is gonna need one !

Boost retarder? If you mean Boost controller - then yes, its a Greddy Profec BII.

As for Emanae - im wiring it my self, so i can post wiring diagram.

A boost retarder is a device that retards the engine ignition as the boost enters its treshold, you never used one?
with out it, there can be a chance of preigniton ect. have you never used one???

[trd94]

thanks doGGy the wiring diagram would be great, as far as a boost retarder i have seen them in turbo mustangs and such but i did not know you could use them in a celica , besides the emange should help with that, am i right? doGGy

This post has been edited by trd94: Jan 14, 2007 - 7:47 AM

[GTSOwner]

Is a boost retarder included in Martins kit, he is gonna need one !

Boost retarder? If you mean Boost controller - then yes, its a Greddy Profec BII.

As for Emanae - im wiring it my self, so i can post wiring diagram.

A boost retarder is a device that retards the engine ignition as the boost enters its treshold, you never used one?
with out it, there can be a chance of preigniton ect. have you never used one???

I *think* the emanage takes care of that.

[doGGy]

Is a boost retarder included in Martins kit, he is gonna need one !

Boost retarder? If you mean Boost controller - then yes, its a Greddy Profec BII.

As for Emanae - im wiring it my self, so i can post wiring diagram.

A boost retarder is a device that retards the engine ignition as the boost enters its treshold, you never used one?
with out it, there can be a chance of preigniton ect. have you never used one???

Why the hell do i need such thing when i have Emanage and i can fully adjust Ignition / Air/fuel maps in any place at any conditions.

Never used such thing - cuz i always try to have as much control over the stock ECU as posible, so instead using somthing like you offered - i ussualy use EMS or somthing like Emanage PiggyBack to have full control.

[Bitter]

no megasquirt2? its a full standalone for 1/3 the cost of the EMS.

[Alan]

Is a boost retarder included in Martins kit, he is gonna need one !

Boost retarder? If you mean Boost controller - then yes, its a Greddy Profec BII.

As for Emanae - im wiring it my self, so i can post wiring diagram.

A boost retarder is a device that retards the engine ignition as the boost enters its treshold, you never used one?
with out it, there can be a chance of preigniton ect. have you never used one???

Why the hell do i need such thing when i have Emanage and i can fully adjust Ignition / Air/fuel maps in any place at any conditions.

Never used such thing - cuz i always try to have as much control over the stock ECU as posible, so instead using somthing like you offered - i ussualy use EMS or somthing like Emanage PiggyBack to have full control.

Ok didnt know it can be used as a stand alone gl then ill be seeing the progress guys

[doGGy]

no megasquirt2? its a full standalone for 1/3 the cost of the EMS.

In this case - no MegaSquirt. Ussualy - for all the bigger setups MSQ is the first choise over all the Stand alones. But the problem is what there is only 1 guy who is able to setup MSQ here in Lith propertly. As i said before - i ussualy dont do any tune-ups cuz i know like 3% about tuning all the ecu's So im leaving this operaion to a pros.

In the 7A setup (on a stock internals) there is no need for a Stand Alone at all - cuz 200hp is almost a limit for a 7A, and for 200hp tune up - Emanage is the way to go - Cheap and good to tune up.

[presure2]

no megasquirt2? its a full standalone for 1/3 the cost of the EMS.

In this case - no MegaSquirt. Ussualy - for all the bigger setups MSQ is the first choise over all the Stand alones. But the problem is what there is only 1 guy who is able to setup MSQ here in Lith propertly. As i said before - i ussualy dont do any tune-ups cuz i know like 3% about tuning all the ecu's So im leaving this operaion to a pros.

In the 7A setup (on a stock internals) there is no need for a Stand Alone at all - cuz 200hp is almost a limit for a 7A, and for 200hp tune up - Emanage is the way to go - Cheap and good to tune up.

good call doggy.
megasquirt is nice, but it can be a bit of a pain to get up and running properly..
good to see the leakdown test results were in order, that is always a good thing.
good work on the fabrication on the ic and stuff!
cant wait to see the results!

[malpaso]

I would agree that unit can handle that "boost business". Although I don't know about that much (what I don't find on web I don't know ), I believe text below answering a lot...

...
cant wait to see the results!

Tell me about that

[doGGy]

Update Got the Valve cover gaskets, still waiting on the main seal where the camshaft and ignition module connects... Still waiting on the Flanges for all the stuff what will need to be fabricated. I think everything will be started tomorow - or at worst case wednesday...

[RoadDawg]

Hey, nice project Is the turbo kit from one of your machines doggy ? I wouldn't mind to get my 7afe turbocharged by you guys, afterall it's only a 8 hour drive for me

[doGGy]

Hey, nice project Is the turbo kit from one of your machines doggy ? I wouldn't mind to get my 7afe turbocharged by you guys, afterall it's only a 8 hour drive for me

Hey Nice to see my old Front bumper

Yes the turbokit came from my Old ST. But it would be easy to build another kit for me actually. So its not a problem at all if you would be intrested, the main problem is time

[doGGy]

OooOoOOK - here we go Finally.

Got all the stuff what i was waiting one, so i thought its about damn time to start works.

Here are all the flanges / oil supply fitting / Fuel Rail:


All these where machined by my friend, so i got them kinda cheap for all the stuff and works i paid like 28$

I decided to rework the fuel rail what the outlet of it had the fitting for the hose, instead of leaving the stock FPR in place and connecting the new FPR from it. SO fuel rail had been rescrewed and new fitting made for it:



Got the fitting for the oil supplie witch goes to the block (stock oil pressure sensor place), it has the place for the stock sensor to bolt in, so the stock sensor will work like it was working before:


All the flanges for the oil supply / oil return from turbo / Downpipe flange / and Bov flange. Still i will need to weld the bungs for the oil supply / return flanges - but this is and easy job


Some piping what i bought at local exhaust shop for the intercooler and downpipe (20$ ) :


Valve cover gasket set (new) cuz valve cover is leaking like crazy on Martins car:


And here is the victim Still just sitting in garage and having no idea what will gonna happen


Ooook as for the start - i removed airfilter box:


It wount be needed anymore - so it goes into the trunk

Next thing was to remove the bumper / inner fender plastics / under plastics (what are under the engine) and the front safty bar (witch is "bent" a little ):


After all was removed - next thing is to remove the header / alternator (alternator removal is a good thing cuz it will give you lots of free space to work with the oil supply fitting and it will be easyer to remove the header)


After header found a place on the ground of my garage here is another target what i was aiming at :




Screwed it out and placed my new fitting in the place:


And put the stock one back into the new fitting:


Oil supply was ready
Next thing was to drain the oil out from the engine and remove the oil pan:


Once the oil pan was out it was clearly visible what some one before me removed it (hmmm maybe somthing was done to the engine before....)

Next target was to clear some space around the Turbo, and the main problem was this box with the relays (US 7A might not have this...):


Well after some thinking - this box found her new place near the ABS module:


Now was time to test fit the Turbo header and Turbine itself:


Hmm it sits in the place Still to make it sit in the place and have some room around i had to make some changes to the Radiator, and to the upper radiator brackets. As you can see in the pics below, on the radiator there are bolting places for the A/C fan, they where hitting turbine cold part, so i just had to go and cut them out (hope marting wount be putting A/C in his car pretty soon )


And i had to redrill the moutning holes on the upper radiator brackets to move the radiator more in front of the car:



And i was reaby for the next step, mount the oil distributor along with the oil supply hoses... But then my wife walked into garage - and said ENOUTH so yea... i had to go out and leave everything as is Anyway, still its a friday - so i have to spend some time outside Keep you updated - cuz tomorow i will be working again on this beast. For now whats it.

[OrbitalGT95]

not to hijack this thread but, has anyone ever sent you, or have you ever done any work to any nissan's Romas?

[doGGy]

not to hijack this thread but, has anyone ever sent you, or have you ever done any work to any nissan's Romas?

Is this would be good enouth Nissan Pulsar GTR 550hp >>> (last summer this Nissan saw a 720hp with NOS and when the main aluminium pulley cracked at 7400rpm on a dyne and went out along with the half of the block...) On this car i'v done most of the interior stuff / exterior stuff. I aint ussualy work with the engines (Only Toyota Engines ), but im working along with the biggest Tuning Company in Lithuania (GroundZero) so i think they can build / help on everything..

[Fate]

lookin' good, can't wait to see it finished.

[TomPoz]

Good stuff, Romas - as usual. Keeping fingers crossed for this setup. BTW- don't remove windshield washer tank.

[doGGy]

Back to buissnes - its sunday (ussualy i start my week at sunda ) so im gonna be working whole week again Got alot of stuff done today (basicly all the freeing space / mounting stuff work).
Well here we go again:
First step today was to free some space in the engine bay, so some stuff had to be removed and relocated. First thing was radiator fan - it gets in the way there the downpipe will be - so i aint wanted to leave it there and melt down from the heat - so, there he goes



Once it was removed - i had to make some space in front of the radiator, cuz i was gonna place on the left side in front of the turbine, so it will not only cool down the radiator - but at the same time blow some air from header and turbine. I did the same setup on my Old ST, and it worked pretty fine, cuz Fan fits in front of the radiator like it was meant to fit there But to fit it there - i had to remove the Oilcooler radiator from the old place, cuz it gets in the way there the Intercooler will be mounted.


After half hour here hows the front of the Celica was looking (can you say - Naked ):


Fan was fit in the place:




After some time spent making brackets for the fan, finally - it was fully bolted in the place:


NOTICE - if some one will try to install fan like this - the important thing is to Switch the WIRES of the motor places - When it is installed BEHIND the radiator - it sucks the air in - once you get it in front - you have to make it BLOW the air.


Now was the time for some cutting To run the intercooler pipes, i use different route when most of the people do, so i just cut 2 holes in the front support, this way i make the piping shorter, and easyer to run (different intercooler sizes might need different route, i do my setup like this cuz my Intercooler sizes lets me route the pipes this way). To make everything more understandible - take a look at the pics:
Left side:

Right side:

After i cut the holes i used simple rubber hose, i cut one side of the hose and wrap it on sharp edges of the metal to avoid chatering sound if the pipes will be hitting sides of the holes. After the hose was fitted, i drilled some small holes in all the corners and used some Zippies to hold the hose in place.

Once the holes where done - was time to install custom front support bar what i made long time ago:


After the front support was in place, was time for Intercooler mounting and some messuring for the new IC piping:


After this, next step was to find a place where to mount the Oil Cooler. It was kinda hard to find a place for it where it will get some air, cuz Martin uses Fog lights in the bumper so i couldnt install it in the p0lace where the side opening on the bumper are, so... I found a place for it in the fender, right there the Washer fluid tank is (Tomasz - i left the Fluid tank untouched ):

Its still a permament mount, cuz i will need to make another bracket for it to hold nice and tight + tomorow im getting all the hoses for the Fuel / oil.

Everything installed in the places:



And the last thing for today was mounting the new FPR, so i just made simple bracket for it, and drilled 2 holes in the firewall - and whoala


Tomorow i will start all the welding jobs (IC piping / Downpipe) and will be running some hoses to all the places and etc My plan is to start this beast by Tusday if everything will be ok And then - DYNO tune I cant wait....

[j0e_p3t]

awesome work romas. can't wait to see the final product. martin's a lucky guy.

[Kadett]

Nice work Romas.

Isn't it possible to mount the Oil cooler behind the IC? Because from the looks of it it doesn't get that much cooling this way?!

[doGGy]

update... Was working like crazy to days in a row - and honestly forgot to take pics of the process... Cuz i was all focused to finish this beast today (but i could not do this... its still needs IC piping..)

Well - here are the pics what i took today of the finished stuff:

Downpipe - had to build my own one from the pipes what i bought:



Finally mounted the oil block with the Oil pressure - so now the oil lines are finally finished:


FPR, Boost controller solenoid installed in the place and all hosed up :



Turbine / Header / Heatsheald is 100% fitted and everything connected:


GT-Four fuel pump installed and goes into its home:


Soldering Injectors plugs + installing injectors (valne cover and intake plenum are removed.)


Finally solved the damn Emanage puzzle - cuz i only had wiring for OBD I, but after some research OBD II has the same wiring pinout, only the wire colors are different from OBD I:


Boost controller found its home in the ashtray :


And the finall shot (blurry a bit - i was a bit shaking cuz it got cold somehow in my garage (some one left doors not closed fully...)


Started the engine, everything works perfectly exept i have one major leak in the Turbo oil supply flange... So i already ordered the new one - tomorow will put it in and finish the IC piping... Friday is the Dyno Day - already ordered a place there... So Its getting to the end finally

[playr158]

nice doggy, but no clamps on the vaccum hose for wastegate/bc/turbo ?

[doGGy]

nice doggy, but no clamps on the vaccum hose for wastegate/bc/turbo ?

No clamps cuz its only a test connection To see if everythign is ok. Will fit all the small things / blots / clamps / and etc once i will see what i woulnt need to remove anything from the engine bay. Btw - its almost imposible to remove this hose, i ussualy cut it out if i want to remove them They are heated there.

[celica47]

You should try to get a kit together and sell them for the 7afe, i would be in line for one!

[doGGy]

You should try to get a kit together and sell them for the 7afe, i would be in line for one!

The kit like this would cost around the same $ as 3SGTE swap Its better to just build a kit for eveyone by them self - this way you could just source all the needed parts as cheap as posible. And there would only be few small custom things left what would need to be manufactured.

[malpaso]

...

...

OMG... where is my "red top" ? And where is my little, poor "Beams" sticker? No... That's not my engine

edit: see? Totally different engine... now we know why blurry shot



p.s.: just kidding



This post has been edited by malpaso: Jan 23, 2007 - 3:32 PM

[j0e_p3t]

^^ someone seems excited. everything looks awesome. nice placement with the boost controller.

[malpaso]

^^ someone seems excited. everything looks awesome. nice placement with the boost controller.

Hope that "excited" you mean excited=enthusiastic not excited=peevish . Cuz my aim was to say: "OMG I can't believe those amazing results/change took only two days"... In other words, Romas is just unbelievable...

[Hanyo]

why such a long hose for the greddy solenoid? I mean a shorter hose would make the engine bay look for clean.

[WH95TE]

I like this thread

[devilsden97]

verynice, but arnt u going to melt those plastic/rubber hoses that run ontop/next to the turbo?

[Silver94CelicaOw...]

boooooost.

[hurley97]

boooooost.

haha. I want I want

[doGGy]

verynice, but arnt u going to melt those plastic/rubber hoses that run ontop/next to the turbo?

My ST-T was running like this for almost 2 years - and nothing melted. If the heat in the place there the hoses run would be such high - everything would melt (including radiator and etc etc..) The bigger head source is Header / Downpipe and Turbo hot part. For the turbine - there will be SSteel cover made, Header has a Heatshield, and doenpipe is wraped in heatwrap. So nothing will melt.

As for the long hoses for the EBC solenoid - i like how they run - its look like there are more action going on under the hood So yea

I could just put the 2 short hoses and mount the Solenoid near the turbo - but practicly there is no place there (cuz of teh damn ABS module....)

As for the Updates - Car is running / drivible. Everything works fine (finished everything yasterday), today finished with the exhaust. SO almost everything is done for tomorow.... Exept one small thing as ussualy has to pop out.. The seal in the inition Distributor is totaly out... It leaks like crazy and i will need to manage some fast way to replace it... So more work left...

Will be posting pics tomorow, and some Dyno chart, and maybe some Video Who knows

[j0e_p3t]

^ me want them now.

[95celicastLSR]

hey great job im in the process of buying all the parts to turbo my 7afe....how much boost r u running on the engine and how does the engine react to that much axtra power????

[doGGy]

Not much good news... Im tired like shiz and im out to bed now... WIll update tomorow with pics / info...

We managed to squizze 198hp and 256nm out of this 7A - but this is not the "safe" Hp numbers - cuz we fianlly found the "hole" in tuning with emanage...

MANNY - I WILL NEED your help - cuz i know you are the guru of the 5S maybe you will help me to solve the problem with 7A too - i need all the posible info about running 7A with 3S 2bar map sensor !!!

Well - wait for tomorow to get all the story...

[sinner96ST]

what does 256nm convert to in terms of ft lb of torque?

198hp is pretty impressive, that's like almost double the output of stock motor.

[malpaso]

what does 256nm convert to in terms of ft lb of torque?
...

about 189 lb-ft
(1 Nm = 0.737 lb-ft)

...and I have feeling we will also need this:
1 bar = 14.504psi

[trd94]

WOW!!! that sounds pretty good for hp numbers, hey doggy will you be posting up the emanage wiring setup ? and what trim of turbo are you using? i know i am running a 57 trim t3-t4 with 370cc injectors and a very rough tune i hit 207hp at 15psi but the timing was all over as i only had the safc and the a/f was to rich on the low rpm so we tuned it for 9psi and the timing is set back 3 degrees right now and she runs very rich, i only get 167 hp now but my motor in not suffering , i want to get my emanage in so i can run 12-15psi ,but i am having trouble with the wiring of the emanage and i want to save a few buck on having it insalled by the shop . sorry for the long post but this topic makes me have so many questions.

[doGGy]

Ok, im fresh out of bed And ready to write... yasterday from 10.30am till 8pm i spend in a dyno shop.... It was a crazy day, and it seems like this is not the end - will have to get back to the Dyno next week tusday..

First thing in the morning when i stared my jorney to the Dyno (about 60miles away from me) i was damn worried about the leak in the distributor - but i had no chance to fix, cuz i was short of time - so i thought ok i will fix it at the shop... Took all the tools needed and drove. Once i got to the dyno - al saw what i was missing about 1liter of oil in the engine - the there was not a leak in the distributor - it was a stream!

Started to rip all the things off:



Took everything off - just to find what both seals (one small seal witch is inside of the distributor, and another one what goes into the head of the engine outside distributor) are leaking... Here how bad the leaking was, you can see all the gearbox swiming in the oil:




After all the seals where removed - i had to walk till the nnearest shop witch sell the sears / rubber gaskets, it was about 2 mile walk till what shop And keep in mind we have -15c outside here So it was fun lol, came back to the Dyno all frozen like shiz

Well finally fixed everything - got everything back, run the engine, drove the car all around - no leaking... ahhh


Now off to the Dyno - so we put the car on Dyno - and all the problems came jumping from all the corners... First thing was - we could not log into the Emanage - no matter what software we where using, nothing helped... No change to get online with the Emanage... After like 5 reinstalls of the Emanage software - finally we managed some how to log into it...




First run was with the 0.4 bar (6Psi). Just to check if the last configuration (the one what i had on my ST-T) was suitible or not. Everything was fine - we where running A/F ratio at about 10 - sometimes 9.8 on the wideband (you can imagine how much rich this was ), And running this rich - spark plugs (denso Platinium) said enouth - and started to missfire...

So the densos where toast... The guys where like ok - i will give you the unbeatible spark plugs for free instead of these... So the guy vent to the garage, and came back holding 4 plugs what where looking like they where removed from some 20 years old engine, i was like WTF! And he goes - relax - these are from Audi S2 2.2l 20V engine - witch was running 400hp i was ok ok give them a try These where original Audi spark plugs - and no matter how they looked - they did the job perfectly - no missfiring, nothing!! The ignition was perfect...


Next thing what we woried about was the Tuning of the Emanage... Cuz the guy, who tuned my car before, was kicked out from the job, and this new guy was all crazy about the tuning and etc - he knew about 3 times more then enyone around So he started to tune the emanage (upping the Boost) and the first question was - what MAP sensor you are running?? I was like STOCK... SO he goes - huston - we have a problem It wasnt fun at all for me... The main problem is - what the Adjustments in the Emanage A/F table & Ignition tables are only availibe at the WOT and at the last row of the tables... This gives no room at all to tune up the car perfectly on the cruise mode... For example - no matter what boost the car would be tunning (0.1 or 1bar) the corrections would be the same for all the boost.... This happens becose the stock MAP only sees absolute atmosfreic pressure, and by correcting Injector size - the limits of the MAP are pushed back a bit (if the MAP voltage on the N/A enine on the WOT is 3.6v so now, after the Emanage corrections at the WOT 3.6v are once you hit the boost - and no matter what kind of boost...)

So it was basicly the same as running check valves and fooling the damn map.... Car ran ok on the WOT and Boost - but when trying to cruise - it was running either rich or at some places a bit too lean... Setup wasnt perfect at all...

If we could tune the car at all the posible conditions (different tune on the all posible boost levels) the HP numbers would be way higher... So now im trying to Locate 2Bar MAP sensor just to see if it would help us or not.

We tryed one of the Map sensors what guys use in the MegaSquirt setup (1.5bar map) but the Voltage chart was out of the Stock Ecu range - so it was nono..:


So after some debating and trying to find the best solution - we set the other date for the Dyno at next week - and we will try to do somthing with the MAP...

For the finishing runs - we tryed 11psi - about 0.9bar of boost - but the CLUTCH (DAMN CLUTCH - i said marting - i SAID from the very begining WE NEED DAMN CLUTCH) gave out totaly! It was imposible to even run the car on the dyno - so im not talking about road conditions at all... So we left the Boost controler set at 0.6 bar boost - and i drove home... Car feels ok - its is 100 posible to drive it without major problems - but it is running crazy rich and every time you let off the trotle at about 4K rpm - and hit it again - you hear BOOM coming out of the exhaust cuz of the unburned fuel...

So for now - whats all - Marting - we need to talk about the Clutch situation - cuz I will not let you drive back home with the Clutch like this!!!!


P.S. About Emanage wiring - i will post all the wiring for the OBDI and OBDII guys! just what i dont want to spend time NOW draving everything and writing - cuz time now is my worst enemy cuz the car has to be ready to drive back at next week - Friday.

[presure2]

romas, you should be able to plug a toyota 2 bar map right into your harness, and run the car with that.

[trd94]

take your time man , i dont need the wiring to soon its winter here and i dont drive it to much , good luck with the map and i hope it works.

[doGGy]

romas, you should be able to plug a toyota 2 bar map right into your harness, and run the car with that.

Hmm.. One thing im worried about is what at WOT or at Absolute atmosferic pressure stock map reads 3.6v and if 2 bar map will be reading lets say 4.6 stock ECU might give a Engine check and stall the engine, and might be so what there will be not enouth adjusting on Emanage to correct this (emanage allows only +50 / -50% correction).

[presure2]

romas, read the BGB's..the 2 bar and 1 bar maps work off the same voltage scale. they top out just right about the same voltage.

[doGGy]

romas, read the BGB's..the 2 bar and 1 bar maps work off the same voltage scale. they top out just right about the same voltage.

thats what i wanted hear Manny

[doGGy]

Ooook so the update is what New clutch along with the Pressure plate came into the place of the old... Managed to source the Original Aisin clutch / pressure plate for a fair price, so it will be good for another 10K kms. Martin will have to take care of this later (cuz now the financial problems aint let us install somthing better then stock).

Car feels fast But its hard to test it out cuz roads are all covered in snow So today it will be a bit warmer so i hope i will find some clean road just to push it a little bit Tomorow - Dyno day with the 2bar map - so we will see what in the end we will get out of this 7A.

[malpaso]

geeee... it will be really tight. Hope nothing will go wrong during Dyno tomorrow cuz I will be already in a bus that time . Damn I'm one small step being crazy those days . I wish would be Friday now...

[TomPoz]

Take it easy Martin - Romas will sort everything out with no problem. :-D

[malpaso]

Take it easy Martin - Romas will sort everything out with no problem. :-D

Thanks Tom, I believe Romas will do best he can for sure. What I'm afraid of are facts we already don't know (not until 2nd Dyno day). Same facts like after 1st Dyno day raised (dead sparks, dead clutch, bad MAP...). But now there will not be much time for improvisation... .

This post has been edited by malpaso: Jan 30, 2007 - 3:51 AM

[TomPoz]

Romas, how was it on the dyno? Everything OK?

[doGGy]

Romas, how was it on the dyno? Everything OK?

Its 8am in the morning and im ready to drive to the Second Dyno tune-up. I had to move the Dyno day from Tusday to Wednesday cuz of the clutch problems - so only today in the evening i will tell if everything is ok

[TomPoz]

Its 8am in the morning and im ready to drive to the Second Dyno tune-up. I had to move the Dyno day from Tusday to Wednesday cuz of the clutch problems - so only today in the evening i will tell if everything is ok

Can't wait for the outcome. I can't imagine how Martin is handling his emotions now.

[doGGy]

I let the numbers speak for me

High Boost mode (0.9 bar) 206hp / 296Nm

Low Boost mode (0.5 bar) 176hm / 225 Nm

At 0.9 bar - its imposible to handle it - first of all - wheels spin is crazy (on 14" winter tires - you can imagine ). 2bar map from ST205 - Aint made any changes in our tuning - cuz DAMN EMANAGE makes adjustments ACORDING damn TPS sensor - and only Ignition table is based on MAP.... So stock 7A map at 0.5bar - read 5v... So corections can be done with the Emanage to avoid Check engine... But the problem is what is its damn hard to tune the car cuz TPS sensor and Boost are 2 totaly different thing - and Boosting isnt related to a TPS 100%... Cuz at the one position of trotle boost might be at one number, and in other case - at other nuymbers... So it was HARD to find optimum adjustments what the car would drive normaly...

Now - everything is finally finished - tomorow will be positing Pics and Dyno Sheets...

BTW - martin is on the way here already

[lagos]

doggy... cant you just tune one map for 75-100% throttle and just have emanage interpolate the rest of the corrections?

[doGGy]

doggy... cant you just tune one map for 75-100% throttle and just have emanage interpolate the rest of the corrections?

Lagos - tuning for the WOT - its not a problem - cuz you basicly are tuning at only last to rows of the table - but adjusting Cruise mode - its was hard... Cuz driving condition might change instantly - while the same might happen with the boost - so we had to find optimum mode and tune it up... Its still the car runs at about 11.5-12.5 A/F ratio on Wideband, so its on the very safe side... Sometimes while cruising it hits 10 mark so its abit too rich - but atleast it is safe... Aint gonna talk about fuel consumptions...

[Alan]

doggy... cant you just tune one map for 75-100% throttle and just have emanage interpolate the rest of the corrections?

Lagos - tuning for the WOT - its not a problem - cuz you basicly are tuning at only last to rows of the table - but adjusting Cruise mode - its was hard... Cuz driving condition might change instantly - while the same might happen with the boost - so we had to find optimum mode and tune it up... Its still the car runs at about 11.5-12.5 A/F ratio on Wideband, so its on the very safe side... Sometimes while cruising it hits 10 mark so its abit too rich - but atleast it is safe... Aint gonna talk about fuel consumptions...

What plugs are you using?

[doGGy]

doggy... cant you just tune one map for 75-100% throttle and just have emanage interpolate the rest of the corrections?

Lagos - tuning for the WOT - its not a problem - cuz you basicly are tuning at only last to rows of the table - but adjusting Cruise mode - its was hard... Cuz driving condition might change instantly - while the same might happen with the boost - so we had to find optimum mode and tune it up... Its still the car runs at about 11.5-12.5 A/F ratio on Wideband, so its on the very safe side... Sometimes while cruising it hits 10 mark so its abit too rich - but atleast it is safe... Aint gonna talk about fuel consumptions...

What plugs are you using?

NGK Iridiom 6

[Alan]

Good, quite Hot! as it is slightly rich

This post has been edited by Alan: Jan 31, 2007 - 2:21 PM

[lagos]

ive never used the emanage, so these are more like retarded questions then they are advice...

but, when you tune for cruise, can you just bump down the injector duty cycle far enough to where you see your o2 sensor start to kick in and let the ecu figure out how to take it to a stoich cruise or idle ? then interpolate from there, to your WOT run to make a smooth transition?

[trd94]

so does the 2 bar map help or does it not really matter as far as using the emanage,

[TomPoz]

Well done, Romas. Numbers are impressive. Can't wait for pics and dyno charts, but even more for Martin to come to me and show me "The Beast".

[presure2]

I let the numbers speak for me

High Boost mode (0.9 bar) 206hp / 296Nm

Low Boost mode (0.5 bar) 176hm / 225 Nm

At 0.9 bar - its imposible to handle it - first of all - wheels spin is crazy (on 14" winter tires - you can imagine ). 2bar map from ST205 - Aint made any changes in our tuning - cuz DAMN EMANAGE makes adjustments ACORDING damn TPS sensor - and only Ignition table is based on MAP.... So stock 7A map at 0.5bar - read 5v... So corections can be done with the Emanage to avoid Check engine... But the problem is what is its damn hard to tune the car cuz TPS sensor and Boost are 2 totaly different thing - and Boosting isnt related to a TPS 100%... Cuz at the one position of trotle boost might be at one number, and in other case - at other nuymbers... So it was HARD to find optimum adjustments what the car would drive normaly...

Now - everything is finally finished - tomorow will be positing Pics and Dyno Sheets...

BTW - martin is on the way here already

nice job romas.
hell if the emanage blue can only do fuel correction based on TPS, its not very good for tuning for boost. with the EM ultimate, you can choose which signal its based off. you can use the map voltage, boost pressure, or TPS.

[doGGy]

Oook Here are the final pics of the enine bay and some goodies. Its 7.30am in the morning and after 1 hour im gonna drive to pic up Martin from other city and drive back here for him to see his car and start his journey back home Im still waiting for the Dyno sheet from the dyno guys, i asked them to send it by email...

As for now - enjoy:

[Batman722]

Looks great Romas, my hat is off to you.

you know the first thing Martin is gonna do is paint that valve cover red...

how's the tune for daily driving ? get that sorted out ?

[j0e_p3t]

that is teh sex. major kudos to you mr romas. hands down the best 7afte i've seen. martin's one lucky guy. you should get a video of his reaction when he sees it and post it here.

[doGGy]

Looks great Romas, my hat is off to you.

you know the first thing Martin is gonna do is paint that valve cover red...

how's the tune for daily driving ? get that sorted out ?

Thanks Dustin I hope he aint gonna do what you said Daily driving is 98% sorted out - its sometimes running a bit too rich - but this might be cuz of the Plugs / really cold weather / and having no chance to tune it up on the road cuz roads are all Icy - so no grip on the wheels and no road force acting on the wheels... But its drivible

[ExSane]

Nice Romas! Good work. I'm surprised that you've been able to boost 12.5. I was always thinking you could only hit that much with a fully built 7AFE. But I guess it depends on how you build your setup. And you did good Romas! I hope the dyno results are a happy one.

[TomPoz]

The beauty and the beast. Respect Romas, as usual.

Well, you guys can expect more pics from my planned meeting with Martin on his way home.

[doGGy]

The beauty and the beast. Respect Romas, as usual.

Well, you guys can expect more pics from my planned meeting with Martin on his way home.

Martin is already on the way to ya Tom Just dont get crazy with the car and Boost - let him get home first And on the High Boost mode - the clutch is crying

I will be waiting for the pics and responses from your side once he gets to ya

[OOBE]

Nice Romas! Good work. I'm surprised that you've been able to boost 12.5. I was always thinking you could only hit that much with a fully built 7AFE. But I guess it depends on how you build your setup. And you did good Romas! I hope the dyno results are a happy one.

The people who never even had experience with a turbo 7A started that silly rumor. I've boosted 15 PSI untuned many times and the engine is as good as it ever was. Compression is still 220-220-215-220.

[phonex98]

sorry if im OT a bit here, but is 220 the best possible compression for the 7aFE ? Also, if someone has extra time, could you tell me or direct me to a site that tells me approximately how compression numbers are derived ? (Ie. Is it a function of stroke length, volume... what ?) Thanks!

P.s. Doggy, you are inspiring me to turbo

[TomPoz]

Martin is already on the way to ya Tom Just dont get crazy with the car and Boost - let him get home first And on the High Boost mode - the clutch is crying

I will be waiting for the pics and responses from your side once he gets to ya

So Martin arrived few hours ago. I saw the beauties (Martin's GF and Celica ), the beast (engine) and its heart (turbo). Impressive. We had a small meet with my club buddies and drove home. I was testing Martin with my 320 Nm car but he did not fall behind. Tomorrow after breakfast I will take a closer look at the car in daylight and share my experience with you later on.

[trd94]

Nice Romas! Good work. I'm surprised that you've been able to boost 12.5. I was always thinking you could only hit that much with a fully built 7AFE. But I guess it depends on how you build your setup. And you did good Romas! I hope the dyno results are a happy one.

The people who never even had experience with a turbo 7A started that silly rumor. I've boosted 15 PSI untuned many times and the engine is as good as it ever was. Compression is still 220-220-215-220.

yeah i hit 17psi a few times ,the motor loves the boost but my valve cover seal did not i plan on running 15psi daily once i am done only time will tell

[lagos]

does the 7afe have a knock sensor?