Irace86.2.0's KPower Turbo K24 Swap

[Irace86.2.0]

Almost finished the downpipe. I finished everything, except for the other half of the dump tube that goes from the wastegate to the downpipe. I just have to position it in the hole I made, mark it up, cut the excess material and weld it up. I do also have to drill a hole for the o2 sensor bung and weld that up. Everything I read says to put it around 24” away from the turbo, but in front of the cat. I’ve seen them like 8-12” away from the turbo before, which is why I routed the line through the sound tube hole, but maybe I’ll just mount it lower if that close is too much heat for the sensor.

The front pipe is done. Yes, messy MIG welds. Just getting it done. Lots of noise complaints from the neighbors when the cutting and grinding lol, so no time to waste. I might make things prettier down the road. I cut off the end and welded on a 3” section and Vband end. I also cut off the old hanger and moved it, welded it.

I also took the IC pipes, FMIC, turbo housing and TB to a welder to do all the aluminum.

[ML]

looks awesome dude. Have you considered making a head shield between the coolant and turbo similar to how I did?

[Irace86.2.0]

Originally Posted by ML

looks awesome dude. Have you considered making a head shield between the coolant and turbo similar to how I did?

I considered it. Sometimes those get so hot that they become more problematic than helpful. They are really best if there is an air gap between parts, so I would need to make it double walled like a thermos, or I would need to move the parts back. I don’t have the space for the latter option, and I don’t know if a double-walled shield is in the cards right now. There is a heat wrap around the coolant pipe, my manifold and downpipe will be wrapped, and I have a turbo blanket, so I should be pretty good, hopefully.

[ML]

yeah that is a lot of protection !

[Irace86.2.0]

Downpipe and frontpipe are done. IC piping is done. I just need to install and wire up the EBC, and I need to wire up the flex fuel kit. I’m thinking I could use the same ground and power wires off the 8-pin AC2 connector, and then I just need to run a wire to a DPO port on the ECU. I also need to wire up the IAT sensor.

[alex87f]

Impressive. This looks almost OEM (apart from the welded piping).
What type of exhaust are you planning to run?

[Irace86.2.0]

Berk frontpipe to Greddy Supreme SP.

[Four_wheel_drifts]

Originally Posted by Irace86.2.0

Downpipe and frontpipe are done. IC piping is done. I just need to install and wire up the EBC, and I need to wire up the flex fuel kit. I’m thinking I could use the same ground and power wires off the 8-pin AC2 connector, and then I just need to run a wire to a DPO port on the ECU. I also need to wire up the IAT sensor.

Wow! This looks OEM. Should have been a $20k option from the factory.

[Irace86.2.0]

I installed the GM IAT sensor. I just cut the existing clip off and installed the new clip.

Pic of the BOV position, which has a vac/boost line running to the manifold T.

I installed the turbo blanket.

I need to wire up the EBC and Flex Fuel harness. I have the strut tower spacers to install, and then I have to work on fluids and starting the car. Eventually I will need to go get the AC system charged.

[hedtrip]

So did anyone find a Fix for the dip stick hitting the baffle? Diff stick? trim it? drill a hole in the baffle?

[Four_wheel_drifts]

Originally Posted by hedtrip

So did anyone find a Fix for the dip stick hitting the baffle? Diff stick? trim it? drill a hole in the baffle?

Further up in this thread, or in another, or on FB, Yes, they are drilling holes in the baffle.

[Irace86.2.0]

Yes, I drilled a hole.

[Irace86.2.0]

I’m back in school now, so everything is going slow. I wired in the EBC to pin 18 and to a 12v acc source. I used the method of routing the EBC for high boost under the installation instructions, which is where a line is going to the top and side of the wastegate. The reducer I used for the compressor had its own boost port, so instead of teeing off the 1 port to the turbo and side of the wastegate, I just ran a line off the compressor and one off the reducer. The third line routes from the top of the wastegate to the 2 port, and the 3 port is vented to atmosphere or would route back to the intake.

I connected the battery, loaded the tune on the ESP software and did the start procedure just to kick over the engine to build oil pressure. I added more oil and coolant. I ran out of time.

It wasn’t obvious to me how to program the drive by wire throttle position, nor was it obvious how to change things. I need to add flex fuel, add the EBC, change my injectors to the ID1050s, change the map sensor to a 4bar sensor, change my IAT sensor to the GM one. I’ll have to play with it next Tuesday or Wednesday when I have some free time.

[Irace86.2.0]

So I found some resources for the ID1050 injectors. One seems specifically for the Elite 1500. I don’t know if there is a drop down menu in Haltech that can be selected that enters these values, or if everything has to be done manually.

http://help.injectordynamics.com/sup...075013-haltech

http://help.injectordynamics.com/hel...nts/4053391633


For the Skunk2 4 bar MAP sensor, which is the same rebadged sensor as the k-tuned sensor, the calibration is:

Min voltage: 0.08
Max Voltage: 4.88
Scalar: 838
Load Offset: 31

From an earlier post, I was shown the GM sensor is in the system, but I need to confer that there isn’t some difference between the different variety of GM sensors, as I have the sensitive variety, which might just be more exposed than different.

https://www.ft86club.com/forums/show...&postcount=142