97 40th Turbo Build

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Now this is getting seriously interesting.
I hope to see some different approaches completed
 
I bolted up the manifold and turbo today to see where everything fits and played with the intercooler plumbing. Unfortunately I think I will do without the factory air filter. I will scour the local wrecking yards to see if I can come up with something other than an open element style cleaner.

Manifold and turbo bolted up.
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Trying to decide where I want to run the intercooler piping. Once I determine the final path I will have a piece made out of mandrel bent tubing to reduce the number of places that I could have a leak.
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Two more..
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that is almost just how I ran my intercooler ducting. if you can afford the fancy elbows use em. they wont leak. the elbows make it much easier to position things durring the build as the ducting is more flexable than a solid piece of pipe. you are also using the same intercooler I am. I'll bet you end up sticking a k&n filter right onto the MAF meter. just get a cone and you are done. if wheeling in dusty trails get a prefilter wrap.

I am curious to see how you run your intercooler ducting from the inside of engine bay to the outside. unless you ditch the fachia piece in front that houses the marker blinkers it will be a tricky fit in your current mock up. happy holesawing
 
I probably will go with a cone filter to make things less stressful. I'm thinking of keeping the facia if at all possible. I may do something with the lights to allow more room, I will look into my idea today. Yes, I will be using manrel bent elbows wherever possible. An added benefit of running the MAF sensor where it is in the pictures is that I will not have to modify the wiring harness.
 
That is one reason i end up doing style of turbo below manifold. I like your cast iron manifold, unfortunately, they are no longer available for purchase.

If you relocate the cruise control box, you may able to fit the OE filter by moving it toward the engine firewall. I thought about this idea before i made my log manifold.

Tony
 
I've been doing some work on the build. I cut a hole in the firewall to run the intercooler ducting through, started to mock-up mounting the intercooler, transmission cooler and power steering cooler.
Firewall Intercooler Hole #2.webp
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While getting ready to plumb the transmission cooler I discovered a very rusted OEM hard line where the factory transmission cooler hoses run through the firewall. I will order a new one and use this to plumb my aftermarket cooler. I would hate to see what happens when one of these leaks....
Trans Cooler Hard Line #1.webp
 
Oh, and most of my weekend was taken-up with removing the head to replace the head gasket. Working alone makes one very inventive, but that is a topic for a separate thread.
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you got head! hehehehehe......snickering.....


Serious. If you were going to "tune up" the head, with i guess a port and polish, would you do it before or after it's sent off and pressure tested?
 
re-routing the AT cooler lines

I ended up re-routing mine lower through the front bib as those just interferred with the logical routing. I maintained the one at the bottom of the radiator though so the one out front is actually just serially in line with the return going back to the tranny. Looks great though. The head rebuild will let you turn that boost up a bit more confidently :cheers:

While getting ready to plumb the transmission cooler I discovered a very rusted OEM hard line where the factory transmission cooler hoses run through the firewall. I will order a new one and use this to plumb my aftermarket cooler. I would hate to see what happens when one of these leaks....
 
I ended up re-routing mine lower through the front bib as those just interferred with the logical routing. I maintained the one at the bottom of the radiator though so the one out front is actually just serially in line with the return going back to the tranny. Looks great though. The head rebuild will let you turn that boost up a bit more confidently :cheers:

Mike, that leads me to ask two questions, 1st - aren't you using your Safari ATF Cooler? and 2nd - whether yes or no to question number one, could you snap some shots of your routing and post them up I'm having a hard time visualizing exactly where else you are putting your lines. Thanks! :cheers:
 
ugh. go to the For Sale section :mad:
third picture https://forum.ih8mud.com/showpost.php?p=2018182&postcount=7
second picture https://forum.ih8mud.com/showpost.php?p=2018189&postcount=8

directly below the PWR intercooler is the Mazda RX-7 cooler. It was originally used as an oil cooler, has both in and out on one side with big banjo fittings and also has an internal t-stat (which can be tossed if unwanted). It's been a while since I did this but the transmission fluid output runs to one of the nipples on the bottom of the radiator. The other one on the radiator then has a line going from it to the Mazda one up front, and the out from the Mazda then goes back to the tranny. Make sense? Anyway I used some fancy hose for this from a place out here called HoseMan where they'll make you any and all kind of hose for hydraulics, oils, fuel, etc. You need to use the fancy constnant torque clamps though where it fits onto a nipple.
 

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