Progress Report Single Conversion FD
 

Ok I think I have collected all the necessary components for my single turbo conversion and I finally put it up on jack stands yesterday to undergo the much needed surgery. I am excited to be FINALLY working on it! It has taken about 6 months of collecting parts and I still need more, but I will be putting these parts on in the meantime.

I know that I need a power FC, fuel system, and ignition, but at least the big stuff will be finished.

Shopping/install list:
1. TO4Z Single turbo kit
2. ETS FMIC
3. GReddy compression tube w/ BOV flange
4. GReddy type RS BOV
5. Aeromotive FPR w/ gauge
6. AEM wide band O2 sensor

pics of progress:
http://i216.photobucket.com/albums/c...s/DSC04362.jpg
http://i216.photobucket.com/albums/c...s/DSC04363.jpg
http://i216.photobucket.com/albums/c...s/DSC04365.jpg
http://i216.photobucket.com/albums/c...s/DSC04371.jpg
http://i216.photobucket.com/albums/c...s/DSC04378.jpg
http://i216.photobucket.com/albums/c...s/DSC04379.jpg

Say the airpump was going to be removed. How does somebody get the drive belt to spin the water pump? Is there an idler pulley for something like that. I did some googling on it but couldn't find anything. I saw a thread on here about someone possibly going to make one.

Has anyone chromed/polished/powder coated there UIM and LIM? I want to get that done while I have them off.

Air pump removal pulley kit like the greddy units and rx7store units. You can get them at rx7store.net

Ok I have cleaned the engine up really good from all the oil that was leaking. (bad oil pan gasket) and installed the steel braided oil injector lines.

http://i216.photobucket.com/albums/c...s/DSC04412.jpg

The car looks like a mess right now!
http://i216.photobucket.com/albums/c...s/DSC04410.jpg

Ok so now I am getting slightly closer to completion, its slow going though. I am getting confused and frustrated on where all these vacuum lines go now. I have blocked off my ACV, EGR, BAC, AWS, just hope I'm not screwing anything up. I have a single turbo vacuum diagram, but of course it is very vague.

I have this diagram, but it doesn't show the vacuum hard-line rats nest (the metal tubing with fuel line) and what vacuum lines go to that or which ones get capped off.

http://i216.photobucket.com/albums/c...uumdiagram.jpg

It would be really nice to see DETAILED pics of someone else single turbo setup so I could base what I'm doing off of theirs.

I didn't even use the "A" solenoid...just get rid of all the rats nest solenoids and run the FPR directly to the UIM. The only thing I kept was the fuel purge control with the blue line as far as solenoids.

What you need:
oil injector lines
Blow off valve line
FPR line
Map sensor line
wastegate lines
boost control lines
catch can lines from oil filler neck/and possibly from un-used oil drain on rear iron
if using stock LIM and stock primary rail then you will need that yellow line intact as well for atomization

Thanks for the advice, that sounds pretty simple when you put it like that!

Ok I finally got my heat shielding wrap for my hose to and out of the turbo and now the TO4Z is bolted on and LIM is bolted on. The FMIC is all in place now. I am just going slow at hooking up what vacuum lines I have to put on.

I have a K&N air filter that will bolt directly to the compressor of the turbo. What I am curious about now is if I need to make a collar that goes in between the filter and compressor with a nipple fitting on it to install the vacuum lines coming from the oil injectors. I have seen many pics of single setups, yet I don't see anyone doing this. The stock vacuum diagram shows that these oil injector vacuum lines go to the plastic port in front of the compressor.

According to the diagram a couple of posts above, it shows a vacuum line called 'fuel injector atomization' and it goes to the pressure pipe coming out of the compressor. Is this right? Where do you guys have your injector atomization vacuum line hooked up to?

Pics of the FMIC installed.

http://i216.photobucket.com/albums/c...s/DSC04692.jpg

http://i216.photobucket.com/albums/c...s/DSC04693.jpg

I got everything buttoned up today and I think it it all has turned out really good and looks good too. A serious difference from what it looked like stock. You always get those bit of nerves before starting a car after a major swap, so I tried starting it but it wouldn't start. It cranks over really strong, and sounded like a couple of times that it might fire. Something weird though, is that I am showing only a max of 21 psi fuel pressure. I have the Aeromotive FPR and adjusted it as far as it could go and was only able to get it to go from 18psi to 21. I opened the FPR to make sure the diaphragm was not defective and it wasn't. When I shut the car off the FPR guage read zero. So fuel pressure is bleeding off somewhere, yet I am puzzled because I see no leaks anywhere. Kinda scratching my head on this one. The fuel pump is working and priming, yet I am wondering if perhaps it is not pushing enough pressure through and maybe that the fuel pump is leaking somewhere. Any IDEAS??

I will be doing some more investigating tomorrow.

http://i216.photobucket.com/albums/c...s/DSC04709.jpg

http://i216.photobucket.com/albums/c...s/DSC04711.jpg

http://i216.photobucket.com/albums/c...s/DSC04717.jpg

check inside the fuel tank, look at the pump and line, sometimes there is a small leak in there if you have touched it

The FSM has some good tests for isolating fuel pressure problems. Cap the feed line coming off the firewall and test the max pressure coming from the fuel pump. It should be 70-100+ psi. If you pass that test then you can be sure that everything from the firewall back is in good shape.

Pinch the return line, does the pressure go up?

I spent a long time troubleshooting fuel pressure problems with my car, it sucks. I have dual denso pumps and they weren't building more than 25 psi. I fixed the problem by permanently bypassing the fuel pump resistor and eliminating the relay in the front of the engine bay.

Good info. Yeah actually I did put vice grips on the return line and the fuel pressure never went up even with that.

What was your setup for eliminating the fuel relay and resistor?

I just pulled the relay and jumped the two terminals in the relay box. Use the FSM to find the correct terminals.

This is also a good time to rewire the fuel pump circuit. Chuck Westbrook has posted some good instructions on this forum. https://www.rx7club.com/3rd-generation-specific-1993-2002-16/how-increase-fuel-pump-performance-401691/

Did you install a new fuel pump? If so you may have installed it wrong. If you did, you may have a leak between the pump outlet and the pump housing inlet. Where the o-ring seals. Also, i'm not entirely sure what to do about that injector atomization line either so i hooked it up to the compressor outlet with a t. As for the vacuum source for the oil injectors, what you are going to need to do is use one of these! Your going to thank me for this one. http://www.atpturbo.com/Merchant2/me...egory_Code=BCS
these things are super cool because they eliminate the risk of things falling into your turbo. Also if you are interested this thing is super cool too and i run one http://www.turbohoses.com/velocity_stack.htm
you need to get the filter from them likely and then a silicone coupler from this to your turbo and then you can put the tap in the silicone from the stack to the turbo. If you want too that is. Yay.

--Hank

who makes that water pump pulley.

I looked up this thread you fwd, but it doesn't show anything on how he did it? I'm guessing there is a link on there that isn't coming through.

Yeah I have a Walbro 255 LPH fuel pump. That is actually the thing I am going to check next and see if there is any leaks back there. Thanks for the links on the fittings. I have been wondering if I could fab something like that up and now I don't have too :)

The water pump pulley and alternator pulley is part of the air pump removal kit I got from the RX7Store.net

http://www.rx7store.net/SearchResult...x=0&Search.y=0

Great news! I have isolated the problem. Turns out it was the fuel pump O ring. I hooked some alligator clips to the plug and dipped the pump in a pot water and there it was spraying water everywhere but out the tube. So what I did was to ensure that this doesn't happen again, just cut the flared end off and hooked a fuel line in between the pump and hardline. Tried it after that and now I am holding 40 psi of pressure. I wonder how long this problem has been going on, cuz I have had mad probs with this car before I tore it down for the single turbo upgrade.

Oh yeah, also my bro was tightening the down tube off the turbine and all of a sudden we hear a loud crack. Looking around a bit at the turbo we saw that the flange from the turbine snapped the welds right off the turbine of the turbo. To say my heart sank is an understatement! So he will be taking it to my friends shop and see if he can weld it back together, which I don't see why not.

http://i216.photobucket.com/albums/c...0922081850.jpg

http://i216.photobucket.com/albums/c...922081901a.jpg

The pump is actually backwards in this pic which I change around.
http://i216.photobucket.com/albums/c...0922081943.jpg

http://i216.photobucket.com/albums/c...0922082027.jpg

Broken welds at the turbine of the TO4Z
http://i216.photobucket.com/albums/c...0922082030.jpg

http://i216.photobucket.com/albums/c...922082030a.jpg

http://i216.photobucket.com/albums/c...922082030b.jpg

I finally drive my car down the street tonight. I have the triple pillar pod with Boost, AEM wide band O2, and oil pressure. (more gauges to come) However I notice the car is running reasonably fine, but rich at idle. The A/F is at 10.4 idling. When I start to give it gas or even floor it, the A/F leans WAY out to 17 and higher and the car spits and sputters. I do not have a fuel pressure gauge in the cabin, but the little gauge I have on the FPR is around 39-40 idling, yet when I hit the gas (with the car in the driveway) the fuel pressure drops. Now isn't that bizarre! It should go up.

I should mention too that I am getting NO boost. I think that it is starving for fuel when I hit the gas which is causing it to sputter, which is not creating a enough exhaust to spool the turbo which is why there is no boost. I would not want any boost though if I am running that lean.

Any ideas why something like this would happen?!?!?!

I have the Walbro 255 LPH fuel pump and Aeromotive FPR and that is it for now on my fuel setup. I am wondering if I should change my fuel pump again to see if maybe it isn't keeping up with the demand for fuel. Other than that I am kinda scratching my head right now.

Where did you put the oil injector vacuum lines? Shouldn't it go to the intake of the Turbo?

Also, I don't see any bungs on your intake piping, where do you have most of your vacuum lines going?

I tee'd off the oil injector vacuum lines together and put a little filter on them to vent to the open air. I exhausted this forum to find a clear cut answer where these go. There is much controversy where and what they do. So I went with that setup.

I followed the single turbo vacuum diagram pretty close. The vacuum lines I have left are going into the upper intake on the stock vacuum ports. Others that are not used are capped off.

There is no way that fuel pump is running out of fuel under no boost. Unless of course it is bad. But i kind of doubt it. How do you have your fuel lines and fpr run? do you have your map sensor hooked up? Is this all on the stock ecu or aftermarket? And where did you run the fpr vacuum line? Whats your base fuel pressure set to?

Your fpr should be set 38-42 psi with the vacuum line disconnected. When you plug the vacuum line in to the fpr the pressure should drop to around 30 if it doesn't you probably need to pick a different vacuum port pretty much anywhere after the throttle body.

Your fpr should be set 38-42 psi with the vacuum line disconnected. When you plug the vacuum line in to the fpr the pressure should drop to around 30 if it doesn't you probably need to pick a different vacuum port pretty much anywhere after the throttle body.

has this build progressed?

Funny you mention that, I just figured out a major problem tonight!!:)

After I did the big single turbo install, I pretty much left it alone over the winter. Recently, after more saved up money (I buy nothing on credit) I decided to pull the 7 out and start playing around again.

I haven't been able to figure out the problem as mentioned above until tonight. My fuel line going from the secondary rail to the FPR has been leaking (bleeding off fuel pressure) unknowingly to me. I drove the 7 over to my bros last Saturday and it seemed fine until I would give it gas...it was weird you actually let your foot off the gas and it would then slowly accelerate, give it gas and it stumbles and falls flat on its face!

Tonight I took my UIM off and replaced the fuel line between the 2nd rail and FPR, buttoned everything back together, start the car, and saw that the fuel pressure was staying put at 40. So I backed it out of the driveway and started driving it down the street and INSTANTLY noticed the power that it SHOULD be making. Wow I haven't felt my 7 that way in quite some time. I have the Synapse waste-gate and I set it at the lowest boost setting, around 5PSi, when I did the single turbo install. I wanted to be as safe as possible since I have the stock ECU and stock fuel system. As I was driving it, I only got up to 3 PSi of boost because the wide-band O2 was telling me "Your in the danger zone." I don't want to detonate because of being too lean.

I ordered the Apexi PFC tonight. So that should allow me to drive it without worry of being too lean. So the progress has continued in a very positive way!