LS4 / F40 swap - fieroguru (Page 181/216)
fieroguru MAY 29, 06:22 PM
Spent more time on the smaller details...

Locked down the MAF location. It is about 1" past the honeycomb insert and the connector harness will clear the range of motion of the shifter arm. Once I got it mocked up, I noticed that the intake tube is parallel with the shifter arm... didn't plan it that way, but a very nice coincidence!



Put the finishing touches to the oil drain line (3/4" .028" tube).


Started thinking about all the boost related plumbing and sensors... Since this is my first turbo and it is non-intercooled, I wanted to monitor some key parameters: EGT pre turbo, Air temp pre/post turbo, and boost pressure. Here are the gauges I picked up so I can monitor those items:




For boost control, I am going to keep it simple to start with. Manual engine bay mounted adjustable boost control valve plumbed like this:


Here is the manual boost controller (and the EGT probe). Thinking of mounting it up by the valve cover and coils to keep the plumbing short (and hidden), but far enough from the turbo to not be 200+ degrees for when I want to adjust it.


[This message has been edited by fieroguru (edited 05-29-2022).]

fieroguru JUL 02, 06:21 PM
Started working on some of the more tedious aspects of the turbo setup... oil feed, reference lines, and data sensors.

Here is the start of the oil feed line off the multi-port oil bypass:


Here you can see the oil line going over the bellhousing. Also visible is the PCV hard line connection to the air intake tube (filtered & metered air)


This is the end of the oil feed line.


This picture has the connection of the PCV hard line to the valve cover. Also visible is the new adjustable boost knob (button head). I didn't like how small the blue one was and it wouldn't accept the hard lines, so I took the spring and ball and made a new housing from aluminum hex.


The warm side had a sensor boss (pressure), temp boss (not seen - it is downstream of MAF), and boss for the waste gate hard line.


I also welded some bosses onto the turbo manifold back side for the EGT sensor and a hard line to a pressure sensor.




The intake manifold also has an ugly hole right behind throttle body and there are several needed reference lines from the manifold (BOV, PCV (dirty) MAF, vac tank for cutout). To address both, I started making vacuum/boost manifold that will cover the hole in the intake as well. It has a machined boss on the bottom side with an o-ring seal for the intake hole.




I want to get a feel for the pressure ratio of the pre/post turbo as well the exhaust back pressure with an without the cutout open. This 3 in one sensor will give be some visual data w/o needing to actual log it. It will be like the dual temp gauge for the pre/post compressor temp delta as well.



Trinten JUL 02, 11:49 PM
That sensor/display solution is really slick. Can I ask what the brand/model is?

Your oil distribution block setup is clean, so is your hard-line for oil supply to the turbo. Very slick stuff, as always.
fieroguru JUL 03, 07:16 AM
Thanks Vince!

The goal is to have this swap at first glance look like the previous naturally aspirated swap with very little exposed wiring, hoses, hard lines. That will be a challenge as there are close to 20 lines and sensors added just for the turbo setup. A few weeks ago I added a page to my wiring file for the swap and detailed out all the extra lines and sensors. For the sensors I decided on what really needed to be logged and what only needed some basic visibility to (gauge only data). This is what lead me to find the dual temp gauge and the triple pressure gauge.

Here is the link for the 3 in 1 temp gauge.
https://www.amazon.com/gp/p...00_s00?ie=UTF8&psc=1
Trinten JUL 06, 09:27 PM
So I realized that the sensor a 3-in-1 for PSI -- which you did state. I guess I just read too quickly.

If you (or anyone) is looking for a similar display that has multiple temp inputs, this is one I found so far:
https://www.autometer.com/2...t-elite-digital.html

I want to setup something like that so I could monitor transmission temp and (something else to be finalized, there's a debatable list here).
fieroguru JUL 07, 06:52 AM
Vince, this is the dual temp gauge I am using to monitor pre & post turbo air temps:
https://www.amazon.com/gp/p...02_s00?ie=UTF8&psc=1
zkhennings JUL 14, 11:58 AM
Looking good as always Guru! Do you have any concerns with the oil drain for the turbo getting backed up under heavy acceleration?
fieroguru JUL 14, 08:34 PM
It is one of those things I will have to evaluate to know for sure. Worse case, I have to add a scavenging pump.

To help maximize the drain performance, it is hard line vs. rubber, 3/4" vs. 5/8 (or smaller), is positioned in the portion of the oil pan right behind the factory opening - which means the oil would have to slosh a bit to
flow back through the drain, and most WOT runs should be limited 10 to 11 seconds.

fieroguru SEP 02, 05:37 PM
I have finally reached the end of the major fabrication for the engine/transmission/turbo and cradle. Finished up the alternator and ac brackets and put everything back in the car for one of the last (but probably not the last test fit). The alternator clears the cross support by about 1/4" and the mechanical water pump clears the side frame by about 0.1". Overall I am pretty pleased and looking forward to finishing up all the final welding on the cradle and exhaust and moving onto the wiring and plumbing.












ericjon262 SEP 04, 06:37 PM
I see you have no intercooler, are you planning on water/meth injection? a while ago "Engine Masters" on motortrend (or maybe it was Richard Holdner) ran a comparison of water/meth vs intercooling, the biggest issue they ran into was that it appeared the water meth distribution was very poor in their LS barrel ram intake. if I remember right, they installed probes in the intake tract to monitor performance. some people have run pre turbo water injection, I suspect the distribution would be much better, however I imagine a downstream MAF would hate that.

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