FD single turbo conversion: complete installation instructions
 

Ok so I am about to embark on the single turbo upgrade on my FD. I spent some time searching and this was the only link I found with any real decent info/links to help. This link here www.negative-camber.org/crispyrx7/gt35rpage1.htm" will be very helpfull in a few weeks when I start to rip apart my engine bay but I do however feel it is a bit long winded but very helpful none the less.
My plan is to document my own install, step by step and post it on the forum in hope for it to become a helpfull sticky for others. Remember I have not purchased a kit, the ones we get over here are pretty crap so most of it has to be fabricated etc.

So here i go, my list of current mods and single turbo plan.

current:
13b REW fd engine, large extend port, 3mm unbreakable apex seals, balanced rotors etc (all done and biult by RX-7 Heaven), 99 twin turbos running 1 bar boost, greddy front mount intercooler kit, Greddy 3" front downpipe, 3" exhaust system, apexi power fc, HKS pod filters, HKS RE050 racing plugs, NGK leads and a 48mm alloy radiator. Currently making 303HP at the wheels.

to come:
GT3540R Garrett ballbearing turbo (turning up tomorrow), RX7 Heaven single turbo manifold (steam pipe), 48-50mm wastegate (still undecided on brand), HKS BOV, RX7 Heaven 3" downpipe, sard FPR, Walboro or bosch fuel pump.

and later:
bigger injectors, greddy profec-B II, Defi fuel pressure guage and the rest of the stuff I forgot to mention above :)

This will be my first fd single turbo conversion, I know the twins intimatley so in theory this should be far far easier.

wish me luck :P

Hey dude, sorry to hijack your thread, but I am heading down the route (single etc etc) soon as I can, except probably a TO4Z.

Has Tony tuned your PFC before? And how did he go with that? --- It's my understanding he's only been tuning PFCs for just over a year.

Might stop by there some time and check out your car.....

Cheers

You should definitely rebuild the engine first before deciding that everything is finished and go for a tune.

all good man, Tony and Brent did a really good job tuning my engine, I managed to get 303rwhp (226kw) and even tony was impressed with the power considering the mods I had. I will be going back for a re-tune once I have my single installed. I know he has only been doing it for a short time and others can do it for sure but most of the others dont know rotary's and how to set them up whereas Tony has been playing with them for many moons! Has your engine been dowelled?? Cause if you plan to run high boost with the T04Z then you need it to be dowelled.
Oh and feel free to drop by but my car wont be at RX7 heaven, I will be doing most of the work on it here at my work Carson Racing out in Glenfield.

Good to hear from you.

is that meant for me or evilg?? my engine has only done 3500kms since rebuild so im sorted for my new power injection for now.

nice, should turn out good. rx7 heaven do some good work.
I live in howick so they are very close to me.
I saw a montego blue FD getting towed through manukau the other day- was this you?
Iv got a white FD with a black roof, blitz racing rims, and a full kit and a big ass loud exhaust so yell out if you see me around :)

nah that wasnt me mine is 99 rx7 innocent blue mica and i can still drive my car for now. I may have to take the car down to get the manifold made though it will have to be trailered then as it wont have any turbos or exhaust on it, I will see what happens next week :)

Not overly sure about that..... It wasn't too long ago that Tony wouldn't tune your car if you had 2mm apex seals ...... guess it depends on what you mean by high boost.... I am looking at around 20PSI ish... maybe a little more

KiwiRE tried to tell me I needed to dowel my engine for boost over 12 PSI.....

It's all a load of shit, demonstrated by many people making much higher horsepower reliably.

I will however be going the WI route... so that will definately count for something!

If you ever see a white FD with a C/F mazadaspeed bonnet and full C-West kit floating around, that will be me :) I also live in Howick so you might spot me 96fd3s

Ok guys and girls, I have started the single turbo conversion and have already pulled off my twins, dismantled emissions rail, replaced the fuel lines etc and I am in the process of tidying everything up while I am waiting for my manifold to be built and delivered.

So far what i have:
GT3540R Garret turbo
M&H 60mm Wastegate
RX7 Heaven Single turbo manifold (should have by tomorrow)

I am waiting on my emissions blanking plates to turn up and need to get my braided lines made once I get the manifold so I can get the measurements etc. I should have it up and running by Monday, fingers crossed!

So far the information I have found most useful I have found here on RX7 Club.com, www.negative-camber.org/crispyrx7/gt35rpage1.htm and rotary resurrection. i will be combining a DIY single turbo conversion with information from both and also my own input as I have found along the way.
For those who are about to embark on this project themselves, it is not a small task and if you are not too clued up when it comes to working on cars in general then i wouldnt attempt this type of job.

Anyway Here are some pics so far.

how were you only making 303whp at 14.7lbs of boost?

Spark plugs had a part to play as well as my fuel system, I am now running HKS (Nippon Denso) racing plugs and I am about to upgrade my fuel system. We had to play with the A/F mixture etc as it was breaking in the high rev range, with more fuel and better plugs I should have made 350hp

Ok so I have been pretty busy over the last couple of days and today it all came together, I picked up my manifold yesterday form RX7 Heaven and today I received the heat wrap for it and picked up my oil and water lines. There are a few things I have to sort out in regards to rerouting certain things so it doesnt look rough and half arsed.
This afternoon after I bolted the manifold and all the lines up and the turbo (thanks Garrett for the awesome design on the last bolt position, it was fun ) I chucked everything back on, put my new fuel lines on the connectors and started the car up. It is running a bit rough (not idling) but that's expected due to not having the intercooler plumbed up, O2 sensor plugged in and blow off valve unattached due to not having a home for it yet. I have taken a few pics on my progress and will be starting the instructions once the car is finished and up and running properly. On Monday I will be trailering my car to RX7 Heaven to have my down pipe and intercooler pipe made so it is then drivable, it will only be running low boost at first until I can get the new fuel pump and reg, then it will be tuned on the dyno once again.

and some more pics

Good work..keep it up. I look forward to tuneing it for you.

See you soon.

yea i just started doing my single conversion

i was going to do 4x850cc and non sequential setup at 17 psi but that was just waste of time and wouldn't be enough

i got the intake manifold out ,twin, rats nest

my question is what do u do with all them wires-(not vacuum lines ) that are disconnected do u just trace them all the way back and eliminate them

that is the only thing i couldn't find any info on an i see from pic that u all ready did that