Matts Budget 1.9 150 SRI

[matthewp1633]

Just thought I would give it a shot to see what it looks like!

[matthewp1633]

[JOHNBOY]

I like them .... did you buy them like that or is it something you’ve put together yourself?

[matthewp1633]

I just did it myself to be honest

[matthewp1633]

So I was sitting around looking for a nice set of seats when what did I find for sale?

turbo welded to insignia injectors.jpg

This is a GT22/56V welded to an insignia exhaust manifold!

The more observant will notice the turbo is the wrong way around with the inlet facing the wrong way. So I guess some thinking is required on how to run the piping....

new turbo piping.jpg

The picture above is from a previous owner of the turbo.

The issue for me is I wish to retain the AC so I considered running the turbo inlet from air box above the turbo outlet. Obviously it will suffer from heat soak as that is above the exhaust manifold.

The other option is to swoop the battery and air box so the air box is close to the turbo inlet. I will need to extend the MAF wiring to allow for this, bu the battery being moved will shift weight away from the lighter gearbox end. This may cause traction issues for the N/S/F wheel.

I already have the 80mm MAF and 4 Bar MAP sensor bought secondhand so the whole set up has cost less that £250 so far! The remap will be a cost as will the intercooler piping but the potential is obvious!

I guess I can sell my current Turbo which is only a couple of months old and has a billet compressor wheel and still has warranty.

[matthewp1633]

I have the de-cat pipe that was specially made to fit from the turbo to the downpipe so its all systems go!2256 turbo.jpg

[matthewp1633]

new turbo fitted.jpg

So finally the turbo is fitted I ran the Air inlet along the sub frame at the bottom to maintain coolness. I used as much metal piping as possible but the pipes kept blowing off.

I rectified the issue by Tig welding a bead along the end of the pipe that had been cut to give a better seal and this solved the issue.
new turbo pipe route.jpg

I did have to remove the Air Con pump to allow the turbo to fit as it is much larger but I just obtained a smaller Aux belt to allow for this

The oil breather pipe was routed to the alloy inlet pipe from the catch tank. I had to fit a completion clutch to take the expected power increase and I must say I was surprised the pedal remained soft and smooth with no stiffness.

Once it was all fitted I went for a run to log data to send to Mr teapot and today I have received my Remapped file to upload. Once I have uploaded the Remap I have to do another power run and send him the data so he can push the boost higher than the 31 psi in this Map.

He is expecting my standard High pressure fuel pump to be the next issue so I am hunting for one now. The 4 bar MAP sensor and 80mm MAF have already been fitted, so here we go.....

[matthewp1633]

So at around 250ish bhp the fuel pump had run out of guts and demand started to lag behind what was required, a new fuel filter was fitted and premium fuel and injector cleaner run through the system, however I guess only so much can be expected of a pump designed to run at much lower pressures. I obtained a free set of 327 insignia injectors from a student of mine who works in a breakers yard.

An R80 pump was obtained from a Facebook page and Mr Teapot prepared the remap with the boost level set to 2.6 bar or 38.22 psi in old money. A considerable boost increase from the 20ish standard psi setting making clear why so much more fuel was required.

I have attached the previous data file to show the fuel pump lag for those who are interested.

[Dog_Book]

Sounds like a right weapon

[matthewp1633]

Sounds like a right weapon

I ve got to be honest even without the pump and injectors its seriously rapid but to make full use of the Turbo I need the pump and injectors. At the moment I am running what Mr Teapot calls a mild setting with 2.1 Bar boost but I must say I am looking forward to the final results. With the Torque and the way the Turbo delivers boost its great fun and the whole thing probably cost around £500.