TD04 swap preliminary report + ?(finished)

Binford · Post by **Binford** » Fri Jun 24, 2005 5:04 am

I started swapping my turbo for a WRX turbo and intercooler tonight. It looks like it won't be as easy as I thought it would be, but it doesn't look that hard, either. Pics can be seen here:

http://www.thawa.net/gallery/album99

I'll have to cut and extend the y-hose and re-route the EGR hoses. Can anyone tell me if I would be all right if I put a plug in the intake manifold and eliminate the line beside the coil pack in pic #3?

THAWA · Post by **THAWA** » Fri Jun 24, 2005 6:10 am

90-94 Legacys don't have an EGR system. What line do you mean?

Binford · Post by **Binford** » Fri Jun 24, 2005 6:15 am

I'm actually referring to the crankcase vents, sorry. The line in particular I'm questioning is the one right next to the coil plug in pic #3.

THAWA · Post by **THAWA** » Fri Jun 24, 2005 7:16 am

The PCV valve?

Binford · Post by **Binford** » Fri Jun 24, 2005 7:32 am

I don't even know where the actual pvc valve is on this car, but I'm pretty sure the valve isn't inside this hose! It runs from the intake manifold to the plastic "tree" that goes to the intake "box"(not the air box) that gets replaced during the "coffee mug mod" I don't see a purpose for this hose, really. I hope I'm not making it too complicated by the way I described it. Do you see the hose attached to the manifold right above the molex plug for the coil? That's it.

Matsumoto · Post by **Matsumoto** » Fri Jun 24, 2005 1:07 pm

The valve is screwed into the manifold at that spot. That's what the hose is attached to. I don't think plugging it is a good idea. The PCV system would not function correctly and it would probably run like crap, if at all.

Binford · Post by **Binford** » Fri Jun 24, 2005 2:01 pm

I see. I didn't realize the valve was there. Thanks.

-K- · Post by **-K-** » Fri Jun 24, 2005 7:42 pm

Plug it. The manifold, take off the tree fitting and run one breather.
My old car needed the same work as yours to fit the turbo/AWIC. It runs fine as long as you leave some place for it to go. I think I routed all the breathers to before the turbo. If I did it again I'd run them all into a catch can.
You can ask Nick (the new owner of the car) how it runs!

Subtle · Post by **Subtle** » Mon Jun 27, 2005 1:10 am

Hi
I have a Perrin " Y " silicon hose that goes from a WRX turbo to
the top-mounted intercooler, as well as the stock intercooler.
Had a custom installation on a front- mounted IC instead.
Both are for sale.
bobhoye@shaw.ca

legacy92ej22t · Post by **legacy92ej22t** » Mon Jun 27, 2005 3:47 am

Bob Hoye-Just a heads up but you should start a new thread in the "parts shed" if you want to sell something, not post it in a thread that has nothing to do with your parts.

Binford · Post by **Binford** » Mon Jun 27, 2005 5:17 am

Ya, I myself already have all the parts I need for this project, minus a few little things I need to pick up tommorrow.

Binford · Post by **Binford** » Wed Jun 29, 2005 4:23 am

Updated the pics. I got side-tracked by repacing the water pump and timing belt. I also spent a night getting my Turbo New Yorker running and brake hose replaced. I had a custom intake pipe bent up today, but I'm having him bend up a new one out of 2.5" pipe instead of 2.25". Should be up and running tommorrow.

PeteGLH · Post by **PeteGLH** » Wed Jun 29, 2005 6:00 pm

Turbo New Yorker

Awesome car even if it's a TD...TI, TII, 2.5 TI??
I miss those cars....

Keep us posted on the TD04 mods, I'm doing the same thing to my SS in a few weeks on my vacation

Binford · Post by **Binford** » Fri Jul 01, 2005 5:43 am

Now that the cops left, I can post.

I got it all together, check out my new pics.

I'm having some problems, though. It won't idle, and it stumbles as soon as it hits boost. I have a couple questions.

1) Is the igniter supposed to be grounded?

2) Is it OK that I have four seperate breathers? I have one on each valve cover, one under the turbo into the block, and one on top of the engine, seen in the pics. -K- said to run ONE breather, so I had to ask.

3) Does the MAP sensor hose plug into the intake? I don't remember where the line was plumbed. That is the MAP sensor on the stock boost controller, right?

That is all I can think of for it to run like this. I am open to other suggestions. Thanks!

-K- · Post by **-K-** » Fri Jul 01, 2005 6:54 am

The MAP sensor is tapped off the passenger side front intake runner.

I would run the crank and head vents into a catch can with a breather. The only problem with your setup is if you get a lot of oil from blowby all over the place, the number of vents doesn't matter as long as you don't build up pressure in the crank.

I don't think the igniter needs to be grounded but it's easy to bend the mounting bracket and bolt it out of the way above the clutch filler.

Binford · Post by **Binford** » Fri Jul 01, 2005 1:44 pm

I re-ran the MAP sensor hose-no success. Another thing may be the fuel filter. I slapped some new fuel hose on without installing the fuel filter. I tried using a generic aftermarket one becuase it is smaller, but the nipples were too big, so I figured it would be all right to do a test run without one. Would this affect my fuel pressure? I'll reset the computer, and try again tonight.

Binford · Post by **Binford** » Sat Jul 02, 2005 12:54 am

Ok, I added breathers to hoses too hastily. The one on top of the engine needs to be hooked up to the intake, since it is not part of the PCV system, DUH! I temperarily spliced it in with the bypass hose since that was quick and easy. I'll weld on another nipple to my intake to seperate them. BUT, something's still not right. It idles and drives fine, but it is slow as hell and cannot feel boost AT ALL! Boost guage reads 9 psi, and I can hear the turbo, but it seems fluttery. I don't know if my quick fix is the cuase of this or what.

Binford · Post by **Binford** » Sat Jul 02, 2005 7:00 am

I reset my ECU and tightened up some hose clamps, and that seemed to help. It still read at 9 psi and was noticably slower than stock was at 11-12 psi. I installed my mbc and discovered I need a new one.

There doesn't seem to be a sweet spot anymore, either it's wastegate pressure or running 16+ psi. I have it in a spot where it sometimes works, keeping boost aroud 11-12, but is not consistant. I'll be ordering a new one shortly.

When it does stay in the 11-12 psi range, I like it alot. I drove it around for awhile and it seemed to learn around the improvements, as it kept feeling better and better. I'm still not sure on the fluttery noise it makes, though.

Subtle · Post by **Subtle** » Wed Jul 06, 2005 6:14 am

legacy92ej22t wrote:Bob Hoye-Just a heads up but you should start a new thread in the "parts shed" if you want to sell something, not post it in a thread that has nothing to do with your parts.

Thanks, I'll give it a try.
Bob

free5ty1e · Post by **free5ty1e** » Wed Jul 06, 2005 1:39 pm

fluttery noises in a turbocharged car are usually not good... compressor surge? When do you hear it?

Binford · Post by **Binford** » Thu Jul 07, 2005 6:34 pm

The fluttering is from the bypass valve, when I shift or let off the gas. I don't know if it's normal or not, and I do have to re-route some lines yet, too.

I switched the boost controller around the other way, and it feels great! 11-12 psi in every gear, and it pulls very nicely. It's finally consistant, and I have some improvements to make yet.

farfrumwork · Post by **farfrumwork** » Thu Jul 07, 2005 10:29 pm

what does it boost from 5500-redline?

I am looking for a bit more boost, as the VF11 runs from a max of 12/13psi (@3.5k or so) to 9/10psi at 6k+. I'd like 15 max and 12/13 at redline (without spending $7-800 on a 16g)

tdo4's are cheap cheap cheap

Binford · Post by **Binford** » Fri Jul 08, 2005 5:58 pm

Boost spikes to 13, then levels out to 11-12 psi all the way to redline. At least it does in second gear, I don't have enough time in first to watch it

, and I haven't been up to the top of third yet.

Binford · Post by **Binford** » Wed Jul 13, 2005 6:45 am

I'm going to re-do some of this. I'll be getting a WRX coolant tank and mounting it on the passenger side, getting rid of the breathers on the valve covers, and some more pcv upgrades(back to factory setup!). All in all, I'm very pleased with this set-up. We'll see what 15psi and water injection feels like!

turboleg91 · Post by **turboleg91** » Wed Jul 13, 2005 7:06 am

The igniter dose need to be grounded, thats why it has those poky washers so it can scrap throught the paint and get a better ground. i did a wrx top mount and turbo and they both dont fit worth shit in my car so ive gotta do a frount mount and sise saddle the old turbo which will look bad ass and work so much smoother.

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TD04 swap preliminary report + ?(finished)

TD04 swap preliminary report + ?(finished)

=)