4.2 Envoy Turbo Build

ConeKilrAutoX said:
This is everything except my 2 TiAL 38mm wastegates and hardware, my efans, my 45 degree bends for down pipe and then my oil tapping supplies.
I am good to go when it is warm!

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1. 06 TB complete engine wiring harness
2. 4" AEM Dry Flow air filter
3. Oil Catch Can + In/Return hosing
4. 2.5" GReddy universal polished aluminium intercooler piping kit
5. Maf conversion + 4" pipe for correct air flow results
6. HKS SSQV III Blow Off Valve with 2.5" intercooler pipe
7. AMS Evolution intercooler (30" x 7")
8. Glowshift BAR boost gauge and Oil Temp
9. GT45r Turbo (balanced) 4" intake and exhaust is 1.00 A/r
10. 2 x 1.5" greddy wastegate piping
11. Aftermarket Exhaust manifold that is reinforced
12. Vacuum splitter (billet machined) for my blow off valve to know when to open or close and for boost gauge reading
13. 3.25" to 3" down pipe converter
14. 3.25" downpipe
15. 06 TB PCM tuned for boost, injectors, maf and more by Limeswap.com (limequat)
16. 80lb/hr 875 CC Deka IV Long USCar injectors
17. 3" U bend from JEGS for fabricating the turbo up pipe
18. 3" J bend from JEGS for fabricating the turbo up pipe
19. 3" 90* bend from JEGS for fabricating the turbo down pipe
20. PCM Wiring I need to pin out C1
21. EV6 Injector Wiring harness
22. Intake manifold gasket
23. Oil feed line kit
24. machined 3" to T4 turbo flange plate
25. ATP Turbo studs (10mm) and 10mm Copper lock-nuts
26. Powerstop brake pads front and rear.
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Pretty :)


Is it too late to move the maf in front of the turbo? That's the way that Autoroc and I are setup. I think you'll get cleaner, more laminar flow than with using the reducers.
 
I would put the MAF pre-turbo as well, you can do it either way but Im with Jeremy and would prefer it pre-turbo. :twocents:
 
Took out the stock fan and installed e-fans
Took out intake manifold, throttle body, fuel rail + injectors

Began looking at wiring to start replacing everything with the 06 wiring harness friday-sunday.

Got the PCM in the mail from limequat ! all ready to go in as soon as im done with injectors, oil catch can, and wiring harness

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View attachment 26638old injectors. havent put the new ones in yet
 

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I see cooling being a problem, under extended load. E-fans with no shroud, only sucking through 2/3 of the area of a radiator that's under-sized for full shrouded e-fans, anyway...

Mike
 
agreed thanks for the input and i will possibly be looking into a shroud down the road but I have no real traffic problems where I live and most of my driving is done at 40+mph in which I believe will be substantial air flow to cool the radiator. I also do not have an a/c system and no a/c condensor blocking any air flow in front of the radiator. my original fan was not sucking much air at idle and the fan clutch was going bad.
 
No, efans are great in traffic. Where they fall short is long periods of high load at low/medium speeds. Like running corners up a mountain, or towing. You will be helped in the airflow dept. by not having the condensor out front, but we really don't get a ton of airflow, and the radiator is under-sized, anyway, which is the reason for the high output mechanical fan from the factory.

Mike
 
oh I see what your saying. I do not tow anything but I will look into a shroud for sure later on.

For some reason I just thought we got more air at 30+ speeds because with the stock fan my front mount transcooler and engine temps dropped dramatically on the high way and 45mph driving and seemed to heat up the most idling in traffic so thats what I based my conclusions on. My friend is running the same efan setup on his lt1 caprice and had to cut holes in his shroud to let air thrugh at speeds because the shroud ended up hindering air flow.
 
With the mechanical fan, it got hotter in traffic because the fan speed changed with engine speed, so the fan was going a bit slow at idle. The stock fan probably moves twice as much air through the radiator as your efans, with the engine at 3000-3500rpm, though. Also, just loafing along down the road or highway, the temps will be cooler, but loafing along isn't what I'm talking about. I could see your current setup with the turbo engine having trouble cooling if you're running hard up a switchback mountain road at relitively low speeds and relitively high loads, or if you're doing stoplight to stoplight to stoplight drags without a low load break between them.

Mike
 
Oh man.. reading this thread and knowing i have a near complete turbo setup in my garage (bought an L61 setup from scorpio a couple years ago)... so tempting
 

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i doubt you'd run enough boost on a stock bottom end for it to be an issue.
 
There should be no issues with the stock Intake manifold holding that amount of PSI.

Tons of people have boosted 03+ ecotec cavaliers and sunfires with 20psi+, they have a very similar plastic intake manifold design, oddly similar actually, but they held up fine to extreme PSI's, so 8-12psi should be fine in the TB's slightly bigger Intake mani.... the only reason I can see for ditching the stock I.M. would be for a better surge tank style intake, and that won't provide any significant gains in HP to PSI ratio unless your talking big PSI, like 20+.
 
scorpio1 said:
There should be no issues with the stock Intake manifold holding that amount of PSI.

Tons of people have boosted 03+ ecotec cavaliers and sunfires with 20psi+, they have a very similar plastic intake manifold design, oddly similar actually, but they held up fine to extreme PSI's, so 8-12psi should be fine in the TB's slightly bigger Intake mani.... the only reason I can see for ditching the stock I.M. would be for a better surge tank style intake, and that won't provide any significant gains in HP to PSI ratio unless your talking big PSI, like 20+.
Click to expand...

Yep, the I5 guys routinely run > 10 PSI with no problems. Rumor is that the I6 was designed for boost, but we have no hard proof.
 
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limequat said:
Yep, the I5 guys routinely run > 10 PSI with no problems. Rumor is that the I6 was designed for boost, but we have no hard proof.
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If that rumor is true then it also is a good reason why the I6 is like a tank and runs forever NA.
 
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The TBSS I6 TT had slightly lower CR, and different rings is all (IIRC, might have had stronger pistons). Its lived at 400hp since 03 when it was released...

I dont have a reason to build a turbo/supercharger setup for my I6 otherwise I would, I have the SS to go fast in. I still have a sweet spot for the I6, its an awesome engine and pretty dang durable. Yes it has its faults, but considering it was brand new engine and design in 02, there are still a lot of "Gen I" I6s running strong.
 
yes he did all the tuning for injectors and boost etc. great guy!

update is....no good yet haha something isnt working and its flooded and have a ton of junk in the intake and manifold. not looking too good yet car doesnt start right and sounds like a dragster idling before my engine dies. i am going back and checking everything. its definitely not the tuner it is me or the car who is f'ing up but ill keep working on it...


after a complete tear down again and inspecting the injectors I believe 1 or 2 maybe 3 might not have been fully seated in the engine. they seemed loose and I took them out re-cleaned everything (gasoline/carbon everywhere !) and re-installed forcing them in much better. put everything back together and will try again tomorrow (fingers crossed)

:suicide: or i am completely lost and out of money for too much more to buy right now (all the turbo parts are in already though)
 
well things are slow right now. I have been battling the snow for the last week but tomorrow I will be welding some piping. will hopefully get the manifold to turbo done and maybe even the down pipe. I will be putting in my friends nissan skyline (r33) aluminium fan shroud and efans tomorrow too!

things should start warming up so I can try to get it started again and not flood it.
 
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Im sitting here thinking that it would also be easier to flip the manifold over, and bolt on from there. But then I realized that the center 2 mani bolt lugs would be in the wrong location when flipped, and that it might also interfere with the intake. So much for thinking huh? lol
 
TollKeeper said:
Im sitting here thinking that it would also be easier to flip the manifold over, and bolt on from there. But then I realized that the center 2 mani bolt lugs would be in the wrong location when flipped, and that it might also interfere with the intake. So much for thinking huh? lol
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hahaha that would have been great! I am thought out...been thinking every day nearly non stop planning and problem solving since last july haha time to finish this project up!
 
the up pipe is all done and welded. the turbo flange is welded and the turbo looks right at home. I chopped off some of the coolant res. plastic to make more room for the wastegates. when its warmer this weekend I will weld up the downpipe and the wastegate pipes.

note: welds have been grinded and rewelded multiple times and cleaned after these pics
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Can you get the front O2 sensor in?

Looks good, liking the progress!

Going to suck doing suspension work, going to have to pull the turbo to get to the top strut bolts.
 
ScarabEpic22 said:
Can you get the front O2 sensor in?

Looks good, liking the progress!

Going to suck doing suspension work, going to have to pull the turbo to get to the top strut bolts.
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haha yes just barely fits! and I know but I can deal with that haha hopefully wont have to work on it too much.

in another few weeks it should be all done!
 
Damn that looks good sitting there! Fits the opening pretty good, and if you ever need to go bigger on the IC you still have some room on the sides! :yes:
 
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