Project: Mavro Gato - 99 Turbo'd 3L

[FastCougar]

Yep ... that's the plan. It will be my winter project to get this car over 450 whp.

[FastCougar]

Well, I have been picking Terry Haines' brain over the last few days on this subject. Based on our conversations, here is what I plan on doing to resolve my oiling & PCV issue.

*NOTE*
Running this type of setup will require me to use the 2004+ "rear" valve cover since it has an integrated PCV valve. That being the case, I will need to fabricate a holding bracket for the DIS coil pack since it's non-existent on 01+ valve covers. I could always take this approach with my existing valve cover, but it would involve some intricate fabrication with aluminum welding AND take longer to perform. Also, the 04+ engines no longer have the large black oil separator canister between the heads. That area is now blocked off with a plate (In 04+ 3L engines).

1) Remove current oil separator canister between the heads and block off resulting hole. This removes the current PCV valve between the heads.

2) Remove the PCV valve nipple in the UIM and seal up the hole.

3) Replace rear valve cover (nearest firewall) with an 04+ valve cover with the integrated PCV valve.

Optional

3b) Remove rear valve cover and modify it to accept the 04+ PCV valve. This mod will involve improving the baffling as well since the 04+ covers have a revised baffle in the cover.

Continuing ...

4) Run the PCV valve tubing to a sealed oil separator/catch-can to "scrub" the oil from the blow-by gasses. We don't want to be dumping oil into the exhaust when we are at a track now do we? Below is a list of EXCELLENT examples of separators. I personally own two of the Custom Corvette Accessories catch-cans.

5) Run the separator out (vacuum source) to a one-way check valve. This is done to prevent reversion in the case of a backfire. Since I will be obtaining my vacuum from the exhaust, I will be using a stainless steel check valve to help combat the heat. Choose your tubing carefully due to the heat involved (high silicon content).

6) Either run some tubing from the check valve to a nipple on the slash-cut tube in the exhaust, or find a way to attach the check valve directly to the end of the slash-cut tube. VERY important to make sure the slash-tube is at a bare minimum 12" away from the exhaust before attaching anything ... this will lessen the likelyhood of melting anything.

7) On the front valve cover, install a valve cover filter (small K&N type filter) to allow fresh air into the crankcase to help purge the gases.

*NOTES*
I will be fabricating a slash-cut tube myself out of stainless steel tubing. The slash-cut tube will create a vacuum when placed in the stream of exhaust gases. The idea is to cut the tip of the tubing at a 45 degree angle and then insert the tube 1/2 way into the exhaust with the cut opening facing the direction of the exhaust flow. Here is a diagram of the slash-cut tube ... keep in mind, this should ONLY be for draw-thru forced induction applications because you don't want these gases gunking up the compressor & intercooler. Doing this is bad for the environment and there is no need if you are running an NA car. For that, simply install the sealed catch-can in-line with the valve cover tubes. I would recommend 2, one for the valve covers and one for the PCV valve.



Oil Separators:
Custom Corvette Accessories Catch-Can
Elite Engineering Catch-Can
AMW Catch-Can

[gamiller]

I know you want to reduce oil in the intake, but i would think the greater motivation to avoid pressurizing the crankcase via the PCV?

[FastCougar]

They go hand in hand ... I wouldn't know about the PCV issue without the oil being present. Solving one will solve the other ... they go hand in hand ... UNLESS I happen to have a blown seal in the turbo.

[gamiller]

I presume the reason you are relocating the PCV is to get it as close as you can to the rear exhaust manifold in order to tap into it. If you deleted the EGR and/or DPFE, I would think you could possibly use either a bung on the EGR tube or the bung for the EGR tube. Although things would be somewhat crowded, that would be accessible from the current location of the PCV.

[fordrule]

Originally Posted by gamiller

I presume the reason you are relocating the PCV is to get it as close as you can to the rear exhaust manifold in order to tap into it. If you deleted the EGR and/or DPFE, I would think you could possibly use either a bung on the EGR tube or the bung for the EGR tube. Although things would be somewhat crowded, that would be accessible from the current location of the PCV.

just find a brass cap that fits on the egr on the header, drill a hole and insert the pipe. then run the pipe out to where needed. gary has a good point and . i dont know if trevor has a egr tube bung on his headers since he built his headers

[FastCougar]

The headers EGR tube output threads have been capped off and will remain this way. I don't want oil in the compressor, so why would I want on the turbine? No thanks ... my slash-cut tube will go about 12-14" past the turbo ... just after my A/F wideband O2 sensor.

Well, let me start this paragraph with HOLLY ****ING ****! Now, let me end it with this car is INSANE!!!

My father and I went on a drive today since he's in town for Thanksgiving. Long story short, we had to go to my office to retrieve something I forgot that I needed today, so he offered to go along with me ... he wanted to drive

So, I'm in the passenger's side messing with the boost controller settings and managed to dial this thing in. Drum roll please ... 22.1 psi @ 60% duty cycle

I drove on the way home and began playing around with throttle modulation based on RPM and this thing builds boost so quickly if you are above 3,500 RPM it's just insane. How insane? Doing 100 MPH in 4th just cruising, floor it and you break traction. Lean into at that speed in that gear and you start to skip chirp the tires!

I would care to guess that we hit 500+ whp with ease. How do I figure ... I could break traction in 5th after shifting from 4th and then immediately getting back into it ... at only 17 psi!!! Yep, an absolute ****ING BEAST INDEED!!!

[michcougar]

Thats SICK!

[Jameson250s]

oh my lanta....

[wadespencer99]

Wow...awesome! Dynoing again soon then?