-90 C1500 6.2 diesel time to turbocharge the bastard!

[kkari]

Hello every one! im writing a little project story of my Detroit diesel enigined c1500! the truck has been on the road now about a year as n/a engine. Now is time to put turbo on place! i build the motor year a go with new mahle oversize pistons,bearings,cam,seals and everything. Compratio is little under 20:1. Turbocharger is garrett gt35, exhaust manifolds are from 6.5 td engine with my own custom adapter pipes......downpipe is 3,5" and goes down to 2x2,5 under the truck. Intercooler is going to be water to air type but i dont have the parts yet because they dont seem to be exist in the whole country rightnow! when i build the truck and motor it was clear as sky that is going to be turbocharged. So some parts and things are chosen to support the pressuresing thing! Facet liftpump has been under the truck to get better start and give room for the turbo oil returnline. ARP headstuds have been chosen to keep cylinder heads on place etc. I put some pictures when i get the pics to my laptop, now i writing this thing wit tappled oh sorry my pad english writing skills, its been a while when last time wroted

[kkari]

Yes! Finally some pictures. I made the air filter induction neck with HAAS cnc turning machine. Filter neck size is 146mm. Air filter aluminium heatshield is ready. The EGT sensor is in place at left side exhaust manifold in cylinder number 8 port, i think number 7 and 8 are the hottest ones. Downpipe is almost done. Oil return line is ready i have to order some pits and pieces for the oil feed line on monday. Hope you enjoy the pictures! Here in finland it isint so common to tune up this engines usyally people tune mercedes and bmw etc.........

[kkari]

Few more.....

[kkari]

When i fix the trucks frame and body and everything i made some changes. Suspension is rough country suspensions with 2" lift and bodylifted 3". I couldnt lift the suspension any more because the law issues over here so i went bodylift too! Wheels are kmc xd series hoss 17x9" with mickey thompson baja mtz 265/70R17 tires. Body is painted with my own custom matt grey color. i made this truck for my wife actually. i have posted one picture in here i believe...more to come

[UKNOWME]

Keep up the good work

[kkari]

Thanks! i'll try. Today i have make some heat shielding to electric wires, some waterhoses and A/C lines. Heat wrapped the downpipe and start to make heatshield over to turbine housing.

[kkari]

Wuhuu! i finally get the air to water intercooler unit! Its actually half bigger than i plannet but its doesent matter. Pump is Davies Craig epb25 which flows 25liter/min. Heat exchanger is vw golf 1.4 liter engined radiator and the expansion tank from same vechile.....My first idea was install the intercooler straight to inlet manifold by cutting the other end away and make some custom end tank that can be boltet straight to the manifold...this unit what i get is way too big for that so i have to make new plan. Unit is going to be holded in place like a gas tank like a straps or something. The ic have huge inlet and outlet fittings 3.5"!!! i all ready have ordered some silcone fitting that reduces the size to 2.5".

[kkari]

Turbinehousing heat shield and downpipe and first meter exhaust 3,5" stainless or actually it is acid proof. Oh and GB oil line

[kkari]

Today i have been installing the circulation pump, wiring and etc. Now i have to try figuredout how to control the heat exchanger fan! maybe i can control the fan with vss sensor like when speed is over 30km/h the fan stops spinning! I was going to control the fan first with temperature switch but i cant find anything suitable. It should be something about 50 celsius rate switch. I havent found anything but 82 to 98 celsius rate switches.

Oh and if anybody is reading this can somebody tell me how much torque can oem spec TH700 diesel transmission handle!?!

i've got brand new torque converter and full rebuild transmission on place.

[kkari]

Getting there, slowly. I bought ac/dc tig welding machine so i made little bit diferent intercooler assembly and alloy boost pipes! Change the wastegate "clock" little bit smaller boost version original was something about 1,7bar(25psi).....few pictures. Today is the DAY when first start as a boosted engine

[kkari]

Ou i forgot the new intakemanifold! non egr single plane or something! one more!

[kkari]

Yes it runs! and beatuful it runs! its been snowing outside few days now and i dont have studded tires so i cant go test drive it well i have to wait until next week and make reserve some dyno time. Oh and have to drive the truck to mot(every year techical inspection) because its now turbo charged i have to prove that is isint too powerfull, i love finnish laws about car and trucks......

[kkari]

Dyno paper......max boost was 10.8 psi at 1600 rpm and goes down to 8.7 psi at 3000 rpm. C code pump fuel screw turned to bottom. No timing adjustments was done because lack of fuel was out standing. Max torq. 579.4Nm(427.3ft*lbf)@1600rpm. Max power 122.9kW(167hp)@2660rpm. Egt:s was maximum of ~400cel.(752Fahr.).

[crashz]

Wow- good numbers! Were they measured at the rear wheels? If so, the torque number is outstanding.

Good EGT's too. 1000 degrees F is about max before melt down.

[kkari]

101.4kW at the rear wheels, drivetrain power loss 18.1%. I'm not sure about the torque number, probably engine....the paper is weird anyway torque curve is really nice! More to come with completely new J-Code pump, custom alloy "wrc" style intake manifold and maybe little different exhaust. All the way 3 ,5" with one muffler. Maybe little more boost and lots of fuel and of course tuning the injection pump timing spot on. I'm pretty confident that i can get the engine produce strong 200hp and 800nM. The old c-code pump is tired almost 249000 miles on it

[kkari]

And i need more heat to the turbine so egt's must go up little bit. they will go up when i get the new pump and more fuel and proper pump timing. Heat is power to a point of course!