sporadic's Turbo Duratec build #2

[sporadic]

Originally Posted by 1turbofocus

Datalog ?

Tom

Working on that tonight. Haven't touched the car since we talked last.

[sporadic]

Finally time for an update. I had quite the tuning issue where the PCM wasn't providing fuel after installing the new intake manifold. See solution here: Adjusting tune for aftermarket Duratec IM

All is well now and the car screams again. Tom pointed out that my timing was way too low, and it was so that certainly woke the car up. I don't recall why I had my timing jacked so low but that's fixed.

I installed a Cossie knock-off intake manifold. I would ONLY recommend these to someone willing to do some clean-up work with a die grinder. The horns for the intake runners were a mess and there were bits of aluminum that needed removed for fear of them coming off and being sucked into the engine. Also, save yourself some hassle and do not buy one of these manifolds that someone painted already. What a pain that was.
Overall I do like the manifold. Nothing lost down-low on my 2.0 and wakes it up more up-top. What I do not like is the MAJOR heat-soak this thing gets from the head. On a 70* day the intake temps will be around 90-100* while driving. After sitting at idle the temps will climb to 140-150*!! A future project is making an intake spacer, probably just out of silicone.

I also installed a methanol injection kit with a 2gph nozzle. I have it set to come on about 6psi. Max boost right now is 11psi. Intake temps drop almost 30* after it kicks in, and the AFR drops a solid point. I am not running any additional timing. The mix is approximately 50/50 water/meth mixing 1 gallon of -20* PEAK brand washer fluid with 4 bottles of HEET.

At the same time I swapped out the 55# injectors for some 60# to have some head room for the future build.


Intake manifold details:
- The oil dip stick will have to be bent
- The bottom bolts will be a royal pain to get in
- The IAC has to be mounted upside-down in relation to stock
- The IAC bolt nearest to the throttle body will need ground down so the throttle body does not hit it while opening
- When adjusting the tune, see link above. I did not disable the IMRC in the tune.
- The brake booster fitting doesn't fit. Remove it, go to the hardware store and buy the necessary fittings for a 3/8" line. Sorry I don't know the thread size. I already had it.
- Expect a lot of cleaning up on the inside of the Cossie knock-off. Sorry no before and after pictures
- You will lose cruise control because the cruise control clip will come in contact with the IAC bolt. I'm still working on a solution.
- For a 2.0 it does require the older style power steering pump and reservoir
- Trim and reuse the 1/8" fuel pressure sensor hose. Also use a properly sized 1/4 NPT with 1/8" outlet. The FPS seemed a bit sensitive while tuning. I used a smaller diameter hose initially which messed with the pressure readings.
- Expect the throttle bracket to not fit exactly right on the knock-off brand

The IAC bolt that needs ground down. (this is after grinding and it barely clears)


Manifold installed. I put an IAT sensor in the removable panel


Bottom view. PCV plugged. WMI nozzle installed.


IAT sensor grommet installed. I did not use that brake booster fitting in the photo. I also swapped out that little vac nipple for larger one for the FPS


View of where the WMI nozzle sprays into the manifold. It is directly after the throttle body. Note: this requires a one-way check valve in the WMI line.


Hood clearance of IAT sensor, for those who are curious


WMI tank and pump


After panel replaced and stickers applied :)




Hoses run out a pre-existing vent in the hatch


Hood clearance for power steering reservoir


Vac block all hooked up


That's all the progress to report for now. I doubt there will be anything else major going on in 2012. I've worked on it so much that I just want to drive it now.
I do have some cheapy seats that I may put in this year. (they were free)

[Hughesy27]

Nice. Glad to see you were able to get the tuning issues solved. Agreed, those bottom bolts were a major pain. I bought all new hardware for the one I got. Hex bolts helped me out a lot. I got as much stuff out of the way as possible. The bottom middle was the worst for me. Love the wmi, nice job on the install. Look forward to seeing your future progress.


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[sporadic]

More recent photos:



Brake booster. I also installed a 3/8" check valve that is not pictured.


And finally my "beta" solution to the cruise control, since I'll be taking a 5-hour trip this weekend:

[1turbofocus]

I have found that the raid right at the intake manifold is the biggest cause of the intake heating up , block the intake from the incoming raid heat and get cool air going around it and watch how much the temps inside the intake drops

Tom

[SaleenT121]

Originally Posted by 1turbofocus

I have found that the raid right at the intake manifold is the biggest cause of the intake heating up , block the intake from the incoming raid heat and get cool air going around it and watch how much the temps inside the intake drops

Tom

Thanks for the tip, i noticed the same thing.

[Hughesy27]

Checking in to see how the builds going?

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[sporadic]

Originally Posted by Hughesy27

Checking in to see how the builds going?

Nothing going on at the moment. I still need to work on an insulator between the head and manifold, and also wrap the back and underside in reflective heat tape.

I did get a code thrown from removing the IMRC and leaving the flag set to o"1" in the tune. Out of frustration I just removed the IMRC from the stock intake and wired it up! I was in a rush and driving over 300 miles on-way so that's where it sits now. I have a couple lean spots in the tune, but none in WOT.
Right now it is set at 10-11psi, overall running fine and the meth injection is also fine. I need to get my slicks mounted and try to hit the track once this year before they close.

I have no more build plans for 2012 other than gathering parts for 2013. I still need rods, bearings, clutch/flywheel and diff. I'll play with the tune a bit more but that's all.

I do have a full set of poly suspension bushings I need to install at some point. I just hate messing with the pos rusted bolts on the rear suspension.

[Hughesy27]

Glad to hear all is well just seeing if anything new happened. Hopefully you or one of us on here find something to use in between the I.M.

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[koke'sfocus]

I just got the garolite but I haven't had the time to put it on on Wednesday for sure I'm making it Ill let everyone know what's the outcome