Project Type R - Phase 2.5

[Dave K]

New turbo turned up this morning TD05-16G, upgrading as my IHI VF24 can't push past 330bhp, or should I say 320bhp with Manx fuel.

Also the new unit is more robust which I need due to the occasional bit of over fuelling.

As the unit has covered 80k already I knew a rebuild would be in order, this was confirmed when it arrived with a small amount of play in the shaft.

So first to come off was the actuator that revealed how much of the wastegate is used, this will be ported slightly as there is a few mm spare.

Next removing the compressor housing large c-clip holding this in place;

Then remove the O-ring seal;

Compressor blades in good condition;

As is the compressor housing;

Then remove water feed and return 2 19mm banjo bolts and the oil return 2 10mm bolts.

A job for latter will be to convert the compressor housing from 90° entry to front entry;

After a lot of WD40 and patience the main body was separated from the exhaust housing;

Exhaust blades in good condition to;

Next before going any further I marked the compressor wheel and exhaust wheel against the main body. This is because the shaft is balanced and I don?t have the tools to rebalance it.

Compressor wheel removed 12mm socket on the exhaust wheel and 10mm on the compressor wheel nut;

Next strip the main shaft and body, which is a collection of c-clips, bearings, thrust bearings and more clips;

Thats the bulk of the unit stripped just got to wait for the rebuild kit to turn up now.

So whilst am waiting on with the porting, this shows how much of a step there is from the up pipe to the exhaust housing, so next job is to get the grinder on it;

Dont know if you want this Jim for the leggy site as a how to?

Edited June 17, 2008 by Dave K

[Dave K]

And also waiting to go on;

[Cret]

Good stuff Dave! Didn't know you were going for the G! You should have fun when that's on!!!

Might well add it on there, cheers!

That entrance at the inlet is pure nasty! Never thought about doing that on mine when I fitted it. Doh! Next time my motor is out when it's clutch time I'll hopefully be doing header porting and will do this at the same time.

Have you still got that other up-pipe of yours Dude?

[andy_bray]

Dave dude you have been a bizzy tart !!!! It is nice to see the inside of a turbo

Have you got your new camera yet Dave??? My 300d is up for sale soon..

[Dave K]

<< Good stuff Dave! Didn't know you were going for the G! You should have fun when that's on!!!

Might well add it on there, cheers!

That entrance at the inlet is pure nasty! Never thought about doing that on mine when I fitted it. Doh! Next time my motor is out when it's clutch time I'll hopefully be doing header porting and will do this at the same time.

Have you still got that other up-pipe of yours Dude? >>

Yep TD05 is most suited to my needs, try and keep the spool of the VF24 but get 350bhp and a stronger unit.

With about 1.0bar @ 3000rpm & 1.5 bar @ 3800rpm & the headers back on should get a nice hit in the back.

From what I have seen on 22b etc the 90° entry does not cause any problems re flow etc, so you should be fine with your setup.

I have to go front entry as the 90° wouldn't fit and I would also have to change all the pipe work.

So cut the end off get it welded on then machine it out, well thats the plan.

Yes still got it.

<< Dave dude you have been a bizzy tart !!!! It is nice to see the inside of a turbo

Have you got your new camera yet Dave??? My 300d is up for sale soon.. >>

Always wanted to strip one, lets just hope it all goes back together.

No I haven?t, on hold for the mo.

How much you asking out of interest?

[Dave K]

Porting of the turbine housing begins;

Using an old gasket as a guide for the uppipe as it is the same diameter;

And the finished product, looks a bit rough in the pics but its not;

Before porting;

After porting;

And the wastegate got a bit, to prevent boost creep;

[andrew_field]

You have been one busy Tart.

Same rear brace I fitted the other month, why are they so complicated to fit?

[grant_morris]

Bloody hell Dave! Next you'll be putting a 2.5 block in there.

Are the rear strut braces worth fitting?

[Dave K]

<< Bloody hell Dave! Next you'll be putting a 2.5 block in there.

Are the rear strut braces worth fitting? >>

Lol, when it goes pop I may well do that! 67k on the clock it's only a matter of time.

As for the rear strut, dont know only fitted it today. Andy should be able to answer that better than me.

[Dave K]

First job for the weekend was to pull the gems ecu;

Removed from case;

Hope to have it back mid week.

Next job install the rear strut bar, first remove rear seat;

Remove top mount nuts;

Fit rear strut mount, the pink finish blends right in! ;

Repeat on the other side;

Next fit centre bar;

As you can see from the last pic bit of a mess, thats next on the list;

Then before refitting I tidied up the wiring;

An other job to do, fit new 3 pod a-pillar mount;

Anybody after 2 pod a-pillar mount with knocklink remote mount for a classic?

Edited June 18, 2008 by Dave K

[pobiom]

TOP pictures and guides ! keep them coming !

[andy_bray]

Nice one Dave ,Look-in good bud.....Went past your place today and there was some cow SH1T on your road... I would hate going down there everytime I wanted to go out in the car...

[heazille]

<< TOP pictures and guides ! keep them coming ! >>

And all finished for Sunday!!

Ta Ta

Richard

[Dave K]

<< Nice one Dave ,Look-in good bud.....Went past your place today and there was some cow SH1T on your road... I would hate going down there everytime I wanted to go out in the car... >>

Aye, it's all over the place.

And what a stink, mind it clears the head when you got a cold!

[andy_bray]

<<

<< Nice one Dave ,Look-in good bud.....Went past your place today and there was some cow SH1T on your road... I would hate going down there everytime I wanted to go out in the car... >>

Aye, it's all over the place.

And what a stink, mind it clears the head when you got a cold! >>

I did not stop to have a smell Dave......LOL

[grant_morris]

hahah, FPMSL.

That would deffo be Courier headline news.. "...Hold the Press guys, Dont put the headline about the Cat stuck in a tree, I've got a new one for you..."

[Dave K]

Some more toys turned up in the post today.

Yet an other strut brace!

And it came in pink just so it match's the rear;

Also a master brake cylinder strengthener, with pink washer!;

Think that can of matt black spray on the shelf may get used.

Edited June 20, 2008 by Dave K

[Dave K]

Also had confirmation from Gems today that the ecu fault was indeed the voltage resistor.

So all repaired and hope to have it tomorrow if not Saturday.

Edited June 20, 2008 by Dave K

[Dave K]

Rebuild kits turned up yesterday;

Need to get one of them sorted asap due to mapping requirements being brought forward due to running lean.

Did a few power runs yesterday with the logger to try and find the problem with the leaning out issue, but no solution as of yet.

Will have a word with Steve Simpson tomorrow and see if something can be resolved.

Also I had a play with some formulas in the logging software to produce horsepower and torque graphs.

Initial tests where great I was getting bhp/ftlbs in the thousands!! but I don?t think the car is making that much some how.

Spotted a few errors in the formulas and a result.

Initially I was sceptical about this working, taking all the variables into account drive train loss, ambient temp, etc....

And the fact that the car is not running right anyway and the last dyno graph I have for comparison/control was with headers on and done mid summer.

270bhp & 272ftlbs 44bhp down;

Overlaid;

Not bad figures as the standard Type R should make 280.0 bhp @ 6500 rpm & 256.0 ft lbs @ 4000 rpm

However I noticed that I was slowly lifting off the throttle from about 3500rpm according to the throttle log!

WOT from 2500rpm with a slight loss to 3500rpm then it tails off till I lifted at 6000rpm, didn?t want to run it to the redline whilst running lean plus peak power shouldn?t be far off 6000rpm.

So for the final confirmation I superimposed the plot over my TEG dyno run matching the power from 53bhp @ 2400rpm to its peak at 270bhp @ 5200rpm.

And to my surprise it's fairly accurate, I checked the power and torque per 500rpm and they matched up to 3500rpm when I was lifting off the throttle and it starts to come on boost and lean out.

The peak torque of 284ftlbs @ 4500rpm also matches the scale on the TEG graph.

Blue line = torque

Green line = bhp

[andrew_field]

Is that the power at the wheels or converted back to the fly wheel?

[Dave K]

Power is the raw data from the ecu/engine, so it's the flywheel with not transmission loss.

I have a formula for drag loss with the impreza drag coefficient and transmission loss but it dont work yet, only 20bhp/ftlbs lower.

Found on the web that on average a evo/impreza 4x4 tranny looses about 24%, thus should be about 205bhp & 213ftlbs @ the wheels.

[Dave K]

Started rebuilding today, first step clean/degrease the components;

As can be seen the second unit has turned up.

It appears to have come from car that had a blow up by the amount of oil on the turbine blades;

Turbine housings cleaned;

Components degreased;

All ready for assembly;

New snap rings installed to retain the new bearings;

Then fit turbine shaft back in with new piston ring;

Fit new thrust bearing with original thrust ring plus new O-ring;

Next oil deflector and new piston ring;

Alloy insert and new snap ring;

Next line up the turbine wheel with the main housing, with the marks made before disassembly.

Then fit the compressor wheel again lining up the marks then fit shaft nut with some thread lock just to make sure, then torque up.

One completed main housing, no play in the shaft and far smoother rotation;

Then fit completed main housing to turbine housing and re fit clamp;

New oil return gasket;

Re fit oil return pipe;

Modding the compressor housing next.

Edited June 20, 2008 by Dave K

[Cret]

I bet you can't wait for all this to be done & on the car Dave!

I've found software (Dataloglab) that can be used with my power FC/datalogit and can give some pretty accurate power curves after logging runs so I will have a good idea where I'm at with tuning and whether each extra part or bit of map tinkering gives an improvement or not. Think this will be incredibly useful especially over here where we have no dyno.

Apparently it's pretty accurate too. Think it's about $40 so will be a good investment I reckon when I get it.

[Dave K]

At the mo I would be happy if the car ran right as it is, still got ecu issues.

I tried the demo for that but couldn?t get good figures as it has not got a file for an Impreza gems only evo gems.

I ended up with 450 odd bhp! I wish.

But from what I've seen on 22B the boys have got very accurate figures via apexi/datalogit.

That's the same reason I want some form of dyno graph so you can track the changes you make.

Saying that Mr Dangerfield has just moved into his spanking new premises and is due a dyno install, rotormax so I have been told.

[Cret]

I was told a good few weeks ago that he was already there and had his new dyno thingummybob, but that it was only a 2wd hub one.

No idea if that's true of not but I know I for one would rather use some software that costs $40 for as many power runs as I please than paying someone else probably well upwards of 50 quid an hour.

I've downloaded the demo version of it so soon as I have my datalogit back I'll put it to the test....