A 3.4 DOHC Build then... F40 Turbo (Page 22/57) Fierobsessed JUN 28, 04:24 AM quote Originally posted by BV MotorSports: Did you see where I asked you to make me one of your LQ1 dipsticks? Yes, I was going to ask if it was for a 3800 or lq1. Either way I'm going to have to go to the pullit for another donor dipstick, and that will have to wait till it cools off into the lower 100's it's obscenely hot this weekend! On the intercooler plumming, if you have had issues with EMT conduit, I really don't see any harm in a full rubber installation either, but it is a lot of hose! My pump is a cheapie Chinese built unit by "Zhonglongmotor" I've opened it up for a quality assessment, and found its actually quite a good little pump. It's a potted, sealed brushless motor, with a wet permanent magnet armature. So there is really nothing to burn out so far as I can tell. And in testing, at 3.5 amps it throws water out pretty violently. We'll see how efficient it is. I've got plenty of IAT sensors for that! I figure I can make a boost/timing limiting code for excessive IAT going into the engine. I think that's reasonable protection. BV MotorSports JUN 29, 12:08 AM Thanks. Just let me know when you get around to it. Not a pressing issue. She wont be road-worthy anytime soon. Joseph Upson JUN 29, 07:17 AM quote Originally posted by Fierobsessed: Yes, I was going to ask if it was for a 3800 or lq1. Either way I'm going to have to go to the pullit for another donor dipstick, and that will have to wait till it cools off into the lower 100's it's obscenely hot this weekend! On the intercooler plumming, if you have had issues with EMT conduit, I really don't see any harm in a full rubber installation either, but it is a lot of hose! My pump is a cheapie Chinese built unit by "Zhonglongmotor" I've opened it up for a quality assessment, and found its actually quite a good little pump. It's a potted, sealed brushless motor, with a wet permanent magnet armature. So there is really nothing to burn out so far as I can tell. And in testing, at 3.5 amps it throws water out pretty violently. We'll see how efficient it is. I've got plenty of IAT sensors for that! I figure I can make a boost/timing limiting code for excessive IAT going into the engine. I think that's reasonable protection. The heater hose is reasonably priced at Home Depot as opposed to a parts store ~$14 for 10' of 3/4", the problem with the bilge style pumps is that they'll still run with near or complete blockage so depending on where you locate your tank the resistance to flow can be significant (from what I've observed) with a low pressure pump as opposed to those running a Mezzier pump. I installed a bigger tank and placed it in the trunk where before it was up front and placed the initial external pump in series with the in tank bilge pump, 950 gph in tank and 500 gph after the intercooler to help after the first restriction. Nice thing about the low cost bilge pumps is that I discovered a week or so ago Walmart has a nice selection of them. If you have a low resistance system a conservative pump will do fine as my system does not run any cooler with two pumps going and upgraded from 5/8" to 3/4" hose, how ever the coolant capacity gives you more reserve under sustained boost. I'd still like to figure out a way to capture the cold temps of the AC dryer and store it in the intercooler coolant. BV MotorSports JUN 29, 11:45 AM I am running the Bosch "Cobra" pump. It works great and has really good flow in my system. Fierobsessed JUL 01, 08:06 AM I did some more work on the air oil separator system. I really wanted to build one that I could feel comfortable that no oil was going to be sucked into the turbo's intake. It could puddle in the intercooler if it did. So here's the finished product: It will have a few of these stainless scrubbers stuffed inside. This should give the air/oil mist plenty of surface area to coalesce, then drain back into the oil pan. I've decided to T the drain port in with the turbo's oil drain. This way, The air pressure and oil mist from the turbo has a upward facing relief, and only liquid oil should drain back down into the oil pan. We'll see how all this plays out. If anything goes wrong, there will be blue smoke, and I'll be draining oil out of the intercooler. I also worked on the other component in the breather system, The intake collar. I took a short 2.5"X4" Stainless intake connector, drilled a couple of holes in it at the appropriate locations and welded in a 3/8" NPT half coupler, for the IAT, and a 1/2" NPT half coupler for the 3/4" barb that will allow the air oil separator to vent into the intake. Ambient IAT sensor In place The more I look at the FMHE installation, the more confident that it's going to work out just fine. I think there is plenty of space for the fan to pull air into the condenser and radiator. But at the suggestion of my father, It would probably be a good idea to vent the hood. And I couldn't agree more. But I won't consider doing that till I am up and running. It's once again time for a little cleanup in the garage, but the heat is getting oppressive. I am hoping that SPEC can get me my pressure plate in the next couple of days. This way I can pull the engine off, slap it in place and put it back on the cradle, and really start to finalize this whole job. I can't believe it has taken me 7 months so far to get this far. I was hoping it would only be about 3-4 to finish. But then I got a bit obsessive (hence my username). This project is turning out better then I imagined and the scope of the project is quite a bit bigger then I thought it would be. Not to mention FAR more expensive then I could have ever imagined. I'll explain that when this project is done. I've been keeping a record of all that was spent. I think I am right at the point where there are only a couple of things to buy. Just some fluids, some hoses and clamps, and a few other odd's and ends. Joseph Upson JUL 01, 08:25 AM Unless you're running dual IAT sensors that's not the best location for your sensor, it will only measure ambient air temps when you need actual going into the motor, although you have intercooling and will not likely see extreme temps there will definitely be a substantial difference between ambient and boost temps at the throttle blade that could affect your fueling. Will JUL 01, 08:51 AM quote Originally posted by Fierobsessed: It would probably be a good idea to vent the hood. This will have a significant negative effect on your air conditioning. The hot radiator outflow from the hood vent goes straight to the cowl plenum intake for the A/C. I agree with Upson... your fueling will need to be based on an IAT inside the manifold, or as least as close to the throttle as you can get it. If you have extras just for logging, that's fine, but the sensor used for your fuel and spark needs to read the air actually going into the engine. RobertISaar JUL 01, 08:56 AM not that i'm saying it's a good design, but the L67s measure air temps before being compressed.... and those M90s make some heat. Fierobsessed JUL 01, 08:56 AM I've got 3 IAT's. One on the intake, Pre turbo as shown above, one post turbo, and one more post intercooler, but pre throttle blade. The 8F code is meant to work with a true MAT sensor, mounted into the side of the upper intake manifold on the 3.1L, Post throttle blade. It's probably not that big of a deal that mine is on the wrong side of the throttle blade, but there is a bit of cooling that occurs at high vacuum on the inside of the intake. The one post intercooler is the only one that is being used for fuel management, the other two only report to the ALDL as of this time. I added them primarily to help to figure out how the intercooler is doing, as well as to document the changes needed in the tune based on the outside temperature, Joseph Upson JUL 01, 09:18 AM I added a second IAT in the upper plenum itself as a second temp feed for monitoring and noted that you have to be mindful to make sure it is in a direct air stream or you may end up in a dead spot (like between two ports) that doesn't get much turbulence to show true efficiency of the intercooling from what I recall in some differences I was seeing between the sensors. I was testing the effect of the methanol injection which was chilling the manifold below ambient. I need to set it up and test it again.