Turbo conversion

[pingu_turbo]

Im sure everyone is sick of hearing about this, but ill ask anyway. :? I want to get a 1.6 8v turbo somehow. I have saved enough money to be able to afford the courteney conversion, but i very reluctant to go for it as ive heard it isnt 'ideal'. Id rather build my own.

I am fairly competant with engines, but as ive never had a good look at a 1.6 8v T or even a let, im not sure where to begin on the building of it.

The only other thing that im not to clued up on is the electrics, as ive got an e16se I wanted to ditch the afm (i dont see how it can work wiv a turbo) in favour of something else? a map sensor or summit?

Im aware that it is gonna cost mega bucks, and im prepared to get onto it.

Sorry for the essay , but im struggling for info or peeps to help me.


Many thanks
Mark

[Adam Moran]

NovaNeil is the chap you'll want to speak to.

He will post here very soon no doubt

I'm only down the road from you and i know my way round a car so give me a shout if you want a hand :wink:

Ad

[peester]

ditto mate.

http://www.novaload.net/forums/viewtopic.php?t=100671

[pingu_turbo]

Thanks for the replys guys, But it appears not many people know about their own turbo conversions!

[peester]

i agree with you there mate. bit pants, ain't it.

[geordie_racer]

what do you want to know?

if it was my build id start by sorting the mounting of the turbo and actuator(sp.)

if your using after market management then ditchin the afm is no problem you'd just need to wire in a map sensor.

then after this you'll need to sort,

boost pipe routing via intercooler to inlet
intercooler mounting and plumbing
poss new injectors
oil and cooling components routing

anything else you need to know?

chris

[pingu_turbo]

Thanks for the post mate, I didnt really know where to start.
I was planning on using aftermarket management.
Ive got just a few more:
With the oil filter, ive heard it has to be re-located some where. How/where?
Also with the oil cooling, How do i plumb a cooler in for that?
With the aftermarket management, do i need to fit a lambda sensor, or does it depend on the brand? I was thinking of a DTA.

Many thanks again,
Mark

[j1400]

For the oil filter and cooler set up, you need a oil take off plate then on top of that a filter take off plate. You can then mount the oil filter on the front leg on the right hand side there's just enough room, wherever you can fit it really, then you need some braided hydrolyic lines to run to the oil cooler that you squeesed between the inter cooler and raditor. and you're away.

With mappable management you don't need to put a lambda sensor in, it's just somethign you cna choose to for mapping purposes, however on a turbo the ideal AFR is not 14.5 under high boost conditions, it would need to go to a tuner with a WB lambda to be set up correctly.

DTA would be a good choice if you could get neil to give his map as a base so you can get it to the RR to be mapped up.

[NovaNeil]

Hello there,

Yes mine is DTA'd.... The cost to do this (DTA it) on top of the cost of already having most of the Turbo bits (ie:Turbo, Manifold, Intercooler etc) is about ?2000-?2500 the reason for this is there was a lot of hidden factors that I didn't realise when I took on the project. Firstly DTA requires a few things to operate, assuming your going to be running a closed loop system like me (no need for Lamba sensor required) then you will need a crank sensor (My engine didn't have one, not sure if the later dizzyless ones do or not) A variable resistance Potentiometer (the standard GSi Throttle body just has a throttle switch 0-5v I believe, DTA requires a variable one so that it can know engine load (throttle body position)) I used a modded VW Golf one) Then an Air temp sensor has to be added in the inlet manifold. oh and an ignition pack (if you have the early dizzy iginition 8v engine). Ermmmm and apart from a load of wiring thats about all the DTA needs to run... It plugs (sorry wires) into your original fuel pump relay and water temp, and I also ran a boost controller off the system.

Thats the DTA sorted, now the rest of the engine will require:
Lowered compression (decompression plate or pocketed pistons etc)
Uprated fuel pressure/fuel pump & injectors (if you want to run more than about 160bhp)
Turbo of course along with a manifold.
Oil or Water cooled pipes feeding to the turbo to cool it (I had a direct oil feed coming out of the pump.
An oil return hose to the sump from Turbo (I had a linking pipe brazed into the sump.
Intercooler or someway off cooling the charge temp (I had intercooler and Water injection... Or you could use a charge cooler)
The neccesary pipe work linking the Filter to the Turbo.... Turbo to cooler.... Cooler to inlet manifold.
As mentioned a remote oil filter as the Turbo hits the standard one as its sticks out too far.

Then all you need is about 4-6hours on a rolling road having it mapped by someone who knows what they are doing.....

Easy hey.....

Or you could just ask me for a map on floppy disc as I have different ones for different occassions. :D

I think thats all you need to know. I'l post again if I remember more.

[NovaNeil]

Oh I forgot.... You also need a Map Sensor, so that DTA knows when its boosting, and atmospheric pressure.

Neil