The next step, Turbo Charged for $260, thanks to DSM reject parts, ebay and junk yards.
Started turbo project at the end of April 2006.
Up side down 1G DSM Mani used as top mount. Ports match up perfect. Picked up from local DSM'er for $15.
Custom bracket was needed for bottom row of bolts.
Top Row of bolts just need to be drilled.
2.5" Custom Down pipe. Cost=$75 for flanges and bends. Extra O2 Bung=Wide Band ready.
Oil return. It is not a solid peice of metal tubing, there is a joint where high temp rubber hose is used. This allow's a little flexing to avoid cracks in the oil return hose.
The turbo sit's high enough for the oil return to enter in the PCV tube. The oil pan does not need to be dropped, drilled and tapped. The oil return hose goes stright though the PCV tube out the inside end. Crank case pressure can still exit the PCV tube, while oil is drained out the end.
All most done.
T25 Turbo from 2G DSM. Also from local DSM'er for $50.
Ebay Greddy China knock off BOV $40 shipped, actully works! Holds vac and boost.
This is going to start as non-intercooled and with a FMU($40 used) for fuel managment with low boost (Boost gauge cost $30). But why not intercooler it and get real managment you ask? Well, because the car still has a OEM quality replacment clutch, so even if I wanted to make more power, the clutch would just slip that much more.
The A/C and P/S is still functional. This is a Daily Driver.
1G 2.2 Probe Front mount fan's, great fit and only $5 each from the local U-Pull Junk Yard.
This 2.25" Cat Back started life as a aftermarket bolt on Pace Setters. Then I cut off the original raspy muffer and used a different one, then added a real flex joint, and a glass pack. So there's really not much Pace Setters left in it. I know I should go bigger, but I dont feel like making a new one. But it's better then the stock 1-7/8" cat back.
Great quality VDO Boost gauge mounted sleeper style in the glove box. It read's both bar and psi, and I like that it's a lower range, instead of a 30psi gauge that would just go to waste.
Here's the oil feed, if you look close to the left side, you can see the solid feed line, I used a vise grip to pinch the line for a oil restrictor, I just squished the line until I got the pressure I wanted. I'm getting oil pressure form the back of the block via a Ford 2.3 turbo oil feed block screwed into the oil sender fitting. It allow's me to plug the oil sensor right back in and use regular break line for feed.
Official first day of boost..well kind of. I've been running the car around all day with the waste gate disconnected to test things out, look for problems and check for leaks. FMU is still not hooked up, but I just had to hear that turbo spool and find out if that cheapy BOV was gonna work and to know if my hours of labor and money paid off. So I hook up the waste and took it down the block. I slowly brought it up to 4psi and it spooled effortlessly and sounded great. I was kinda surprised it did'nt knock with the crappy 89 octane still in the tank an no added fuel mangment or intercooling. Wastegate is disconnected again untill FMU is hooked up.
Installed FMU and adjusted waste gate to 4.5-5psi. Has a nice strong pull, goes though the gears quicker. It's not insane fast, but fun and that was my goal (plus working A/C!). So far no Check Engine Light. I did try 7-8psi, pulled very well but did start to ping, still has 89 octane in the tank. I'm pleased. Best $260 I've ever spent on go fast goodies.
The stock internal waste gate on the T25 is about 8psi, that's just a little too high for the way I have it set up right now. So in order to run lower boost then the waste gate setting, I disconnected the waste gate from the flapper, and used just a spring (shown here) to hold the door shut with just enough pressure to run 5psi. I learned this trick from HMT, I was surprised to see it had no boost creep and still spools fast.
The FMU. (yes, I know they suck)
Surprisinly the stock 96 1.9 MAF only get's up to 4.5 volts while in boost to 6000 RPM's. And the O2 voltage starts at .9 and climes to 1.0 Volt while at 5 psi. There should be no issues with supply enough fuel. I also dont get any knock at 5psi with 89 Octane, the IAT sensor must be doing it's job.