[Afterhours]

2.0 Zetec custom turbo install almost completed.......

Well, my turbo install is almost completed. I'll give a quick run down for those that may be interested.

Day 1:
-Removed the stock exhaust manifold, catalytic converter and exhaust system up to the two bolt flange.
-Installed turbo manifold and turbo charger.
-Fabricate and install turbo coolant lines.

Day 2:
-Fabricate and install turbo oil feed line.
-Remove oil pan and fabricate fittings for oil return line.
-Fabricate intercooler charge piping from the turbo compressor outlet to the intercooler inlet.

Day 3:
-Fabricate intercooler charge piping from the intercooler outlet to the throttle body.
-Fabricate the stand-off and flange for the by-pass valve (BOV).

Day 4:
-Fabricate turbo intake piping from the turbo inlet to the MAF sensor/air filter.

Day 5:
-Fabricate pipe fitting for BOV vent hose to turbo intake pipe.
-Fabricate turbo down pipe.

All I have left to do is to fabricate the tie-in pipe for the external wastegate to the turbo down pipe, install the larger fuel injectors...............then, pull out all of the piping for painting with high temperature ceramic paint. Whew..........almost done.......
:biggrin:

 

[Loyalty]

RE:2.0 Zetec custom turbo install almost completed.......

Just a few quick questions.....for those of you that have done the Turbo on the Zetec motor, how many of the parts were you guys able to just buy? Meaning was everything readily available in a catalog to order? Also how much total has it cost you? Finally how much HP was gained......

I'm really wanting to get some kinda of power to my car, but not sure how I want to go about doing it yet.......


BTW the install looks great :thumbsup:

 

[Seawulf]

RE:2.0 Zetec custom turbo install almost completed.......

Nice, what size injectors are you gonna install and exactly how are you gonna control them? And which piping are you gonna paint? Remember the exhaust manifold can get hotter than 1500F. My dad painted it with 1200F paint and even at 800F idle temps the paint bubbled and blistered off. If you're gonna paint the charge piping, I think it looks good as is.

 

[HKSCougar]

RE:2.0 Zetec custom turbo install almost completed.......

Oh, yeah baby, bring that sh!t on! I love it! I'm so psyched about getting mine off the ground. I love being back here in the US - I saw more Cougars today than ever (my first day back in five years). But MY cougar isn't here, so I'm kind of sad.

I want to start my turbo kit now!

Good work, man. Keep us posted.

 

[ZetecNinja]

RE: 2.0 Zetec custom turbo install almost completed.......

damn that is alot of fabrication

what about a custom programmed chip?

 

[JAMallott]

RE:2.0 Zetec custom turbo install almost completed.......

that looks really good man! im also interested in what loyalty asked. and do you plan on moving your battery? im surprised it fits in there with the battery! plus, for weight reduction on the front wheels, it would definatly help. just a thought since you are doing so much already to increase power and preformance to your cougar. keep it up though man. cant wait to see it when its finished!


welcome back leibler!!!!!!

 

[Seawulf]

RE:2.0 Zetec custom turbo install almost completed.......

For Loyalty's question. Everything can be ordered from a catalogue but for catalogue prices you're better off going to Focus-power.com and getting Turbo Tom's kit. I got most of my stuff either on Ebay, salvage yards, or custom made. Only the low buck items were ordered through a catalogue, ie. piping, hoses, wires, etc... The manifold can be ordered from one web site, http://www.jgstools.com/turbo/index2.html. The sites changed a little since I was first there so you'll have to hunt for it but it cost around $300. You can make it yourself for around half that price.

As for my prices: 146whp and 156wtq cost $800, 200whp and 210wtq cost an additional $2500-$3000, haven't figure out exactly. That's for everything engine,turbo, exhaust, and electronic parts needed.

And, I'd lose the Breather Filter and install a hose hooked up to a remote oil catch can of some kind, Afterhours. You're gonna get some serious blow-by if you haven't replaced the stock pcv valve with one that can seal under boost. I haven't either so I have a cheap catch can rigged up. You won't see much blow by under mild driving and boost, but at WOT I get some oil in there, so you prabaly will too.

 

[Afterhours]

RE:2.0 Zetec custom turbo install almost completed.......

Hey guys thanks, I've been spending most of my time in my garage so I haven't been on-line much.
The project is coming together pretty well. Yesterday I completed the external wastegate pipe tie-in to the down pipe and I linked it up with the rest of the exhaust system. I just have a few minor details to finish.......then I'll start her up today so I can check for any leaks or other problems.

Loyalty - Like Seawulf mentioned, all of the parts and components are readily available. I've bought my various parts from many different places........like E-bay, catalogs, directly from companies and local stores. I just took my time and looked around to find the best prices on the parts I needed. Up to this point, the total cost for my set-up is around $2,500 which includes engine management. My target HP goal is 225 fwhp, but I won't know the actual numbers until I get it on a dyno.

Seawulf - I'm running 36 lbs injectors for now. When I bought my injectors, it was sold in a set of 6, so I have two extra injectors. I'll have to look at the A/F numbers with my LM-1 A/F meter and see if I need more fuel. If I do, I may look into your idea of running a 5th injector controlled by the E-Manage. I can control the 5th injector's fuel map based on boost pressure.

Yes, I know the manifold will get pretty hot and I don't know if the paint will hold. I'm giving it a shot anyway. I used Duplicolor 1200 degree high heat ceramic paint......and cured the paint at 300 degrees for 2 hours. Hopefully it will hold up..............

The charge pipes look pretty good just as is, but I still want to paint them more for corrosion resistance.
I've decided to leave them as is for now, and paint them later when I have more time.

I am planning on eventually getting an oil catch can.......I just need to decide on a good mounting position. I don't have much space in the engine compartment anymore..:biggrin: What kind of oil catchcan are you using and where did you mount it? Is you PCV system still connected to your intake manifold? To minimize the oil blow-by into the PCV system.......the hose from the PCV valve should be relocated to the intake piping between the turbo inlet and the MAF sensor. This way the you won't be pushing boost back into the PCV valve (which would basically pressurize the crankcase under boost).

JAMallott - I don't plan on relocating my battery. Everything does fit well with the battery there if you route the piping carefully. It is sort of like stuffing 10 lbs of stuff in a 5 lbs bag though.......:biggrin:

Well, I better go and finish up the install. I'll let you guys know how things go after I start her up.

 

[Seawulf]

RE:2.0 Zetec custom turbo install almost completed.......

We relocated the battery, cause at the time we had our first intercooler where the battery sat and to have more space overall. ultimately I would up moving that intercooler to the bumper and then replacing it. It also gave my dad a sense of accomplishment early on in the build since he did that in the first week and the whole setup wasn't finished till the 7th week. Also keeping the battery their would give you a bit more weight up front and might improve your traction vs moving it to the back.

As for the paint, I think that 1200F paint is exactly what we used and my dad also cured it in the oven at 400F for a few hours and this is how it looked after a few minutes at idle, scroll down for the pic. http://www.fastcougar.com/forums/messageview.cfm?catid=48&threadid=89984 Then it started bubbling and blistering and it smelled real bad. Took about 3 days to burn it all off and stop smelling.

As for a catch can, I just have a $2 juice bottle from wal-mart hooked up to a hose on that crank case vent in the valve cover. I have it mounted near the power steering unit on the firewall. I need to do something better, like buy one of those for sale on ebay or make one using plumbing supplies. I'll probably route the hose to vent into the firewall or some other place not in the intake.

And 36s won't take you to 200whp safely. You don't want to run the injectors more than 92% and I'm pretty sure you'll have to do 100% on 36s to get close to 200whp. And for me a safe AF ratio is no leaner than 11:5:1. Good luck and keep us posted.

 

[Afterhours]

RE:2.0 Zetec custom turbo install almost completed.......

I completed the turbo install today and started her up, I let the engine idle for awhile to reach operating temperature........just to check for any oil or coolant leaks.........or any other problems.
It was great.............:banana: No leaks, oil pressure was good, vacuum was good and the EGT at idle was 750 degrees.

Once I was pretty confident that everything was hooked up ok and running properly, I took the car for a short test drive. No hard driving, just cruised around the neighborhood a bit to run the engine through the gears, watched the engine temperature, oil pressure, engine vacuum and EGT's. By the way, the Mil eliminator circuit I built worked great..........no check engine light since I don't have a catalytic convertor anymore................:biggrin:. I noticed that at around 2000 RPM's I could hear the slight whine of the turbo charger............yet between 2000 and 2500 RPM's, the EGT's were between 1000 and 1100 degrees. After 10 minutes of driving around, I brought it back to my garage to double check for any leaks or other problems. Everything looked good.

Once I was sure there was no oil or coolant leaks, I took the car out for a second test drive. This time I did a short second gear pull from 2000 RPM's just to verify the boost pressure setting on the external wastegate and to see where the boost threshold was. The boost begins to come on at 2500 RPM's and hits 6 psi at just around 3000 RPM's. All I can say is............It was awesome!!! I just rolled on the throttle (just half throttle).......and the car pulled HARD. I must say, I'm really pleased with the results of the project. I'm going to baby the engine for a while until my LM-1 wide band A/F meter comes in on Friday...........I really don't want to push the turbo until I get a better idea of my A/F ratios.

Hey Seawulf, you're right about the paint not holding up. The ceramic paint on the turbo exhaust manifold did blister a little..........just a few spots here and there. I'm not sure if it's because of the type of paint, or my prepping of the manifold surface. Like I said, it's just a few spots here and there.....not like the whole manifold is blistering. Anyway, it's not too bad if it does blister off..........the manifold piping (weld els) is black to begin with.........it probably won't be that noticeable if the paint burns off.

Oh baby..........I've got boost............:banana:

 

[Seawulf]

RE:2.0 Zetec custom turbo install almost completed.......

And yes the paint will continue to blister and then bubble and it will give off a very pungent burning smell. But like I said, it will all burn off after two or three days of driving.

YOU EVIL BASTARD You mean I no longer have the distinction of being the only turbo's Zetec on these boards.:banghead: Oh well. :tongue: Welcome to the club.:grouphug::thumbsup:

 

[Ness1216]

RE:2.0 Zetec custom turbo install almost completed.......

Congratulations! Ive been watching your install since you started and it turned out well. Hopefully we'll see some of your stories in road tales soon.

 

[ZetecNinja]

thats sweet man, I wish I had enough knowledge to join the club!

 

[ZetecNinja]

oh yea...wheres the pics & vids??

 

[xangel]

ok...your setup is VERY impressive... :beer: :bowdown:

but I have one burning question

I have seen some of your posts at teamzx2.com

and I have seen a lot of posts about turboing this one particular engine...especially in the Escort ZX2s. Does this cougar use a more boost friendly version of the computer?


are all the statemesnts about turboing the Z-tec a bunch of bunk?

A lot of people say turboing the Z-tec in a ZX2 is more trouble than its worth do to the computer. How did you get around this? It seems like (from what I have read) that you just bolted on a lot of this, and hadn't had to worry about the computer. Am I wrong?



I am a rookie on turbos...so bear with me....

 

[Afterhours]

Thanks Ness1216, ZetecNinja..............doing a custom turbo is not really that difficult. What I would suggest is get a copy of Corky Bell's book....."Maximum Boost". Read up until you really understand the fundamentals of turbo charging. It'll give you a really good idea of what it takes to do this type of project....................and here's a few more pics of the completed set-up from different angles. It's not much different than my "in-progress install" except I have all of the clamps and hoses connected. If you have a particular request for a picture of some part or component............just let me know. Sorry, no vids yet.

 

[Ness1216]

Ive read Maximum Boost about 3 times so far, great book, reading it again actually. I am planning a turbo install as well, I will have a TON of questions later haha. Anyways, what I really need to know about it the little things and a few fuel tuning questions. Right now I am researching on my own if I have any questions left over they will be posted. I am planning on the Garrett GT28RS (Disco Potato) I think It would be good for the zetec. Whats your guys opinions?

 

[Afterhours]

xangel, I'm not sure what your talking about as to my posts on Teamzx2.com. I haven't posted anything there before?

Engine management with any turbocharged Zetec............is a very important aspect of a successful turbo project. I'm using a Greddy E-Manage to control my fuel maps and a MSD Dis-2 programmable ignition controller to control ignition timing. These have been installed prior to installing the turbo. I've installed them before anything else, because I wanted to be sure they both worked properly before doing the turbo. If you search the 2.0 forums, you'll see my install posts on them. More importantly, I'm using an Autotap OBD-II scanner and a LM-1 wideband A/F meter to be able to monitor the various engine operating parameters, such as (wideband) A/F ratio, MAF voltage, Ignition timing, Throttle position, engine temp, engine load, RPM.........etc. This allows me to "see" what is going on and make the proper engine management adjustment when tuning.

Seawulf has been very successful with his custom chip...............and he's putting out 200 hp at 9 psi.
Liebler is planning on using the SCT programmable chip...........which is probably the best engine management solution. Then there's Turbo Tom (from the Focus forums) who has successfully turbo'ed many Zetec motors.

So to answer your question, yes......the Zetec engine can be turbo'ed, but you must also address the engine management issues such as fuel and ignition timing.

 

[Seawulf]

Read all my past posts on my turbo setup and Afterhours posts on his turbo setup and Emanage install and that will tell you a lot. The biggest problem with doing a custom turbo and pushing more than 150whp is the Ford ECU is not easy to get around without a chip and until the SCT software not many reputable chips were avaliable. A chip or a ECU reflash is the best, most economical way to controll the fuel and timing of our cars.

The main reason I'm encouraging Afterhours on using the Emanage is he already has it and I'd like to see what it can do. The problem with the Emanage is it can't control the high power output of our timing spark and will fry the Emanage if you try to hook it up that way. I don't like the fact that all he has for timing is the MSD box. A J&S Safeguard will do the same thing AND it can retard spark when it senses deto.

Ultimately the only problem with doing it like Afterhours is doing is when you add the cost of the Emanage and MSD that's more than the SCT software and around half as much as a Pectel and you still have the stock speed limiter. But when he bought the Emanage the SCT wasn't out yet. If it had been out before I went to StreetFlight, I'd probably have gotten that as well.

Needless to say, look into the SCT software, it will be the easiest way for you to control the computer, fuel and timing.

 

[xangel]

http://www.eautoworks.com/html/ord-auto~performance-Electronics~Product-1-5075.htm

I take it you are talking about this???

Or are you suggesting to go with SCT over the Greddy Emanage?