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ZC TURBO PROJECT DONE! (99%)...Lots of pics - need HELP and criticism! (LONG)
Well, after two long years of collecting parts and selling other things to buy
new parts, I finally have everything on my car. I did all the work over the Christmas break and just finished this past weekend (I'm at school 200 miles away during the weekdays)...I would say it took me quite along time to finish everything (100% alone). Nothing fit. The installation was very frustrating...but I kept at it. Down in central Florida it is usually warm, but during the only time I had to do the setup and install temperatures went down into the 30's and 20's many of the nights...not to mention the damn wind in the afternoon. The only space I had to keep my car was my parents driveway, which is on a hill. I had two jackstands and two small car jacks. I've had my ZC for almost 7 years now and this project has been much anticipated...it was kind of something that kept me going when things got boring elsewhere. All I used was knowledge from the web and prior reading of the manuals, etc. Not once during the entire month of the install did I consult a book or look up how to do something (I realized this in hindsight). So I would say if you plan on doing the full homemade setup make sure you know everything inside and out, much as I did as I spent tons of hours online which made all the difference. Here's the background on what I did / have: 1990 Civic Standard Hatch (ZC swap and Si tranny) Brand new T-25 2nd gen DSM turbo with Randy/Gary's adapter plate Dropshop 2.5" downpipe from Jon Standard (not HF) manifold which was heavily ported Starion rewelded intercooler that I got in excellent condition Volvo piping, couple standard exhaust lengths Blitz BOV and mandrel bent pipe (came with it) Zdyne Gold, 450 injectors (balanced, cleaned, almost made new) VTEC fuel rail, AEM fuel pressure regulator Fuel Pressure Gauge (electric); Air Fuel Gauge, Oil Pressure Gauge Boost Gauge (ISSPro) I'm sure i'm forgetting things but those are the main parts...The T25 outlet hit the x-member...I made small slits in it and used a hammer to contour the xmember around the turbo. This kept all the material and a majority of the local support. I also got hold of a Jimfab front tranny mount (www.jimfab.com) which helped tremendously in keeping the engine still as the downpipe and turbo had very little clearance from any kind of rocking motion. The other engine mounts had long before had the 3M window weld treatment. Doing the install on my driveway greatly complicated things. The oil pan wasn't that bad to get off...every single bolt was loose on the pan (3 were also missing!). The oil pressure sensor was a complete pain...especially laying under the car trying to feel around things. 15/16" or 24mm DEEPWELL is the only sure way to get the thing off...it was also extremely hard to tighten the fitting and line on the rear...The battery had to be relocated as there was just not enough room for me to get the piping the way I wanted it. You can see the 4 gauge wire coming in from the rear in the pics. My car came stock without any AC components and when I got the car the front bumper support was not there...thus making the intercooler install very easy! There's lots of other things in between that I will post on my webpage ( http://members.aol.com/nosajuf/nosajuf.htm ) soon with complete directions on how I did everything. Then about 4:35 on a Saturday night everything was bolted up...I turned the key and started the car. It started right up, barely coughing. The previous tune loaded in the zdyne made it run rough but I uploaded some of the few tunes I had with me at the time and the car instantly changed tone and idled beautifully. Nothing leaked anywhere! Oil pressure was great! The turbo was smoking but my neighbor assured me it was the factory oil burning off the turbo surface (it was new). I let it sit and verified oil in the lines, etc. Everything was cool. Eventually got it out on the road and it reved up so much better than it did stock with the integra computer. Learned how to make the car go into boost...which wasn't hard. I was very easy on it...after awhile got on it just a bit and found it was running 8lbs on the stock setting. The car freaking darted forward under boost. It was very quick and I was quite impressed as I couldn't quite smiling and going nuts...of course I was very careful and stopped constantly to check for leaks as I drove back and forth on a back street (this is out in the country). The Blitz bov sounds great too...big woosh of air! Car finally has boost and is much quicker, but I need help with some things now... BTW, the car has almost 300,000 miles on it. I've put 100K on the ZC alone. First here are some pics... http://members.aol.com/_ht_a/nosajuf/HondaTech1.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech2.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech3.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech4.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech5.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech6.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech7.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech8.jpg If you want to know anything about the pics, let me know. I have questions now...please answer any ones you can!!!! 1. The only program I have uploaded so far is the stock PM6FI tune that came with the zdyne...I have uploaded the TurboZC program Ricky Crow has on the trading site. When the car goes into boost, 2nd gear seems ok but under boost in third and fourth gear the car hesitates or it seems like the boost isn't linear. There are no specific noises or clanks from the engine, but the turbo wont put power into the engine linearilly. Why is it doing this? All the pipes have heavy duty clamps and are incredibly sealed. Will the ZC tune fix this? 2. When going into boost my fuel pressure gauge (nordskog digital) increases with boost...8lbs at full throttle says like 45psi...at idle the fuel pressure is about 32-34psi so it says. Sometimes now the gauge drops down below 30 and then 20 and then 10 until you give it some gas. I'm not sure why it drops...the pump is stock with the car (i.e. 300K miles). I have a brand new walbro 255 already mounted to the stock tank holder sitting in the garage. Is the stock pump shot? 3. When the turbo does boost the bov releases the pressure, but I also hear a faint rattlesnake like noise come from the turbo...usually a quick pssss noise. I can't imagine the bov isn't releasing all the pressure as it's loud...The blitz bov has an adjuster bolt on top of it, should I some- how adjust this? Those are the main problems I have...when I accelerate and go into boost the car doesn't boost linearly, it jerks and buckles, but it seems like it's getting fuel. Air Fuel Gauge is lighting up one light below totally rich. What can I do to get it running right? Thanks, i'm glad the thing is running now... https://honda-tech.com/forums/images...s/emsmilep.gif Jason |
re: zc turbo project done! (NosajCivic)
Isn't it best to maintain a down angled slop with the oil return line? I believe it helps prevent the oil from caking up in the line since it'll never really have a chance to sit.
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Well...
It is angled down just ever so sligthly...the blue silicone tube bends
just a little. It's the only way I could get it to fit. Seems to work so far (for about 15 miles). Jason |
Re: zc turbo project done! (asterix_2ksi)
damn that's a tight fit. looks nice though.
i wouldn't worry too much about the oil return line though, as long as it is indeed angled downwards you should be ok. |
Re: Well... (NosajCivic)
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Ok...
Thanks https://honda-tech.com/forums/images...es/emsmile.gif
Anybody have any ideas on why the boost is doing what it's doing? http://images.honda-tech.com/set1//smile/emcrook.gif |
Re: Ok... (NosajCivic)
nice work man.
brings me back to the installation of the turbo on my car back in the day (only a few months ago) stress,sweat, blood, tears, everything went into that install and ur description of driving it for the first time...smile to my face too https://honda-tech.com/forums/images...es/emsmile.gif congrats |
Re: Ok... (TurbothisLS)
Haha, thanks...
Yeah, many nights I just gave up and went inside...funny how the bolt I couldn't get out that night was easy the next morning...I hear people say how they did a turbo install over night or in one day...i'm not sure how! I guess maybe if I had a hydraulic lift, a welder, something other than a little dremel, a nice workbench (my dad's seemed to work great though) and just plain more room it would have been easier (but that's cheating!)...man I love the sound of the valve and the power that was never there before...yeah this is my first time around with a turbo - i'm freakin' hooked! https://honda-tech.com/forums/images/smilies/emthup.gif Jason |
oil drain flange
is that a Drop shop oil drain flange you got on there ?? did you get that from jon >>??? when did you order and how long did it take to get to your place ?? im ordered one from him and it aint here yet ...
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Re: oil drain flange (project dc2)
your BOV might be set to tight. that "rattle snake noise" is known as compressor surge, you may want to back the adjustment screw out untill you can't hear that noise anymore. https://honda-tech.com/forums/images...es/emsmile.gif
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Re: ! (NosajCivic)
1. I wouldn't go crazy boosting on it until you have a way to monitor air/fuel ratios, the turbo tune that you have may be a good starting point but after all that work you don't want to blow it up.
2. Your fuel pressure should increase with boost and also decrease with vaccum. In this way the fpr always keeps the same pressure difference between the fuel rail and the inside of the intake manifold. If you have a walboro I would go ahead and install it for piece of mind. 3. The sound you are hearing can probably be adjusted out by playing with the screw on top of the bov. |
Re: Ok... (NosajCivic)
You really just need to go to a dyno and get that bad bear tuned. Don't try to street tune it. That'll never work. Trust me, I ran a ZC at 10psi for 2years and never went to the dyno https://honda-tech.com/forums/images...s/emhammer.gif
I'm running an LS with boost now but I went to the dyno this time. I can't tell you what peace of mind that brought, not to mention drivability. The 300 you might spend tuning it is worth more than the turbo itself. Good luck and it looks good. |
Re: Ok... (glagola1)
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Re: Ok...
http://members.aol.com/_ht_a/nosajuf/HondaTech3.jpg
what kind of filter is that on the turbo or whatever it is..? |
Re: zc turbo project done! (asterix_2ksi)
I enjoy your setup https://honda-tech.com/forums/images...es/emsmile.gif
I need to redo my oil return line like no other https://honda-tech.com/forums/images...es/emsmile.gif |
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you have a better pic of the lower charge pipe? and any of your car with the bumper on? the ones on our site are small, and i like the idea of a blue turbo Std hatch https://honda-tech.com/forums/images...es/emsmile.gif
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Re: ... (turbohf)
oh and what color is the paint on the valve cover?
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Re: ... (turbohf)
https://honda-tech.com/forums/images/smilies/emthup.gif on the set up, it looks damn good.i went through the same bs with my zc turbo install. enjoy the boost!
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More pics and ANSWERS...
Answering questions...
First off the filter I had ordered from Discount Auto Parts (now Advance), Cheaper than anyplace online! I went to the K and N website and looked up the dimensions of the filter I needed. This one (RU1880) fit perfect in the small gap I had to put a filter! The inlet to the filter is 2" which is almost the size of the OD of the filter! Half the size of an aluminum coke can with the top cut out. Anyhow it was 29.99 bucks special ordered from Discount Auto. http://members.aol.com/_ht_a/nosajuf/HondaTech11.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech9.jpg The valve cover I painted with Plastikote 285 Cast Grey (500F paint). It is excellent stuff. Doesn't need to be baked on really (per the instructions). It goes on nice, and dries almost instantly...over hot temp paint i've noticed gets all over your hands and doesn't dry right unless you bake the part. This stuff is great. Here's another one of the valve cover. http://members.aol.com/_ht_a/nosajuf/HondaTech17.jpg The charge piping was a complete pain in the arse. I ended up using the three basic pipes as shown. I had a ton of different pipes (they are all for sale on ebay now - Nosajuf) and ended up using hardly any of them. The pipe off the T-body is a blitz bov pipe which angled and fit perfectly! Plus, it had the bov connected already...The next piece is a rubber Fernco connecter (2.5 --> 2.0) from Home Depot. I will probably replace this with silicone once I get some money back. Then a 2" exhaust pipe from Discount Auto parts ran to the intercooler with a stock Volvo 90 deg silicone bend wedge up on it. The 2" exhaust pipe didn't need to be cut as miracuously it fit perfect the way it was. I just painted it the same color as the valve cover. On the other side is a Volvo bend again and a volve pipe. I used all heavy duty clamps. http://members.aol.com/_ht_a/nosajuf/HondaTech13.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech10.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech12.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech18.jpg Here are some more random pics. This shows the stock HF cover that I polished up. That's a STD manifold. Dropshop downpipe... M10 x 1.25 cap head screws I had specially orderded...not many places carry these - trust me! Lots of cutting of the frame...and very little clearance! http://members.aol.com/_ht_a/nosajuf/HondaTech14.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech16.jpg http://members.aol.com/_ht_a/nosajuf/HondaTech15.jpg I hope to have a complete write up soon covering everything. Jason |
Looks good
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Questions...
Car still isn't running right though...won't go past 3 - 4 lbs boost...turbo
is hesitating like crazy. I'm lost. http://images.honda-tech.com/set1//smile/emcrook.gif Jason |
Re: Ok... (accordexchange)
post your spark plug picture after you run it.. and try running it with another air cleaner.. your air cleaner might be the bottle neck.. who knows??
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Re: Ok... (Whooopasss)
Looks great man, congrats! https://honda-tech.com/forums/images/smilies/emthup.gif
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Re: Questions... (NosajCivic)
Car still isn't running right though...won't go past 3 - 4 lbs boost...turbo is hesitating like crazy. I'm lost. http://images.honda-tech.com/set1//smile/emcrook.gif Jason [Modified by 99GSRT, 6:22 PM 1/26/2003] |
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