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

[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.